400kV Switchyard Calculations

Ref.
(4)-G77700-S0019-L061-A
Project:
MESNET IZALATORU MEKANIK HESAPLAR
Gilgel Gibe – II PROJECT

ETHIOPIA
Description:
400 kV SWITCHYARD
DESIGN
REPORT’s & CALCULATION’s
Subject:
Report on Calculations for Determination of
Cantilever Strength of Bus Post Insulators
Note:
This report establishes the sizing of bus post insulators for 400kV switchyard
on the basis of cantilever strength.
BPI Selection Design Report : Cantilever Strength Calculation Page: 3 of 7
Handling: Unrestricted
Contents
page
1. Introduction ....................................................................................................................... 4
2. System Data...................................................................................................................... 4
3. Conductor Data ................................................................................................................. 4
4. Bus Post Insulator data ..................................................................................................... 5
5. Attachments ...................................................................................................................... 6
6. Conclusion ........................................................................................................................ 6
7. References........................................................................................................................ 7
Siemens Power Engineering Pvt. Ltd. The reproduction, transmission or use of this document or its contents is not
permitted without express written authority. Offenders will be liable for
damages. All rights, including rights created by patent grant or registration
of a utility model or design, are reserved.
(4)-G77700-S0019-L061-A
1 Introduction
The rigid bus in out-door substation is primarily supported on Bus Post Insulators. These bus
post insulators are hence subjected to sustain all types of stresses on bus conductor owing to
electrically and mechanically originated forces.
The principal forces on the bus post insulator are as follows –
a. Short circuit current force on the bus conductor.
b. Wind force on the bus conductor.
c. Wind force on the insulator stack.
d. Weight of the bus conductor span supported by the bus post insulator.
Since the forces on the bus-conductors are transmitted to the bus post insulators, the strength of
the insulator must be considered. With various bus configurations, insulators may be required to
withstand cantilever, compressive, tensile and torsional forces. However, only the cantilever
force, which is a function of the effective conductor span length supported by the bus post
insulator, have been regarded significant and considered for design.
2 System data
400kV AC Switchyard
Nominal System Voltage 400 kV
System Frequency 50 Hz
Short Circuit Fault Current 31.5 kA
Duration of Fault Current 1 sec
Maximum Wind Pressure 700 N/m2
Altitude above sea level >1500 m
3 Conductor Data
Rigid Conductor
i) 250/6mm Aluminum Tube (AlMgSi0.5F25)
Outer Diameter 250 mm
Wall thickness 6 mm
(4)-G77700-S0019-L061-A
Weight 12.4 Kg/m
Weight of Damping Material (Twin 954 MCM Cardinal ACSR) 1829.8 Kg/kM
ii) 120/8mm Aluminum Tube (AlMgSi0.5F25)
Wall thickness 8 mm
Weight 7.6 Kg/m
Weight of Damping Material (Single 954 MCM Cardinal ACSR) 1829.8 Kg/kM
iii) 120/6mm Aluminum Tube (AlMgSi0.5F25)
Wall thickness 6 mm
Weight 5.8 Kg/m
Weight of Damping Material (Single 954 MCM Cardinal ACSR) 1829.8 Kg/kM
Common for all tubes specified above
Young’s Modulus 70000 N/mm2
4 Bus Post Insulator data

i) C8-1550
Height of Insulator Stack 3350 mm
Maximum Width 310 mm
Minimum Width 140 mm
Weight of Insulator 349 Kg
Cantilever Strength (designated by manufacturer) 800 daN
i) C6-1550

(4)-G77700-S0019-L061-A
i) C12.5-1550
Busbar Selection
The following types of tubular busbar has been considered in the design :
x 250/6 mm AlMgSi0.5F25 Tubular Bus bar to serve as Main Bus Conductor.
x 120/8 mm AlMgSi0.5F25 Tubular Bus bar to serve as Equipment Bus Conductor at the
Bus Coupling feeder.
x 120/6 mm AlMgSi0.5F25 Tubular Bus bar to serve as Equipment Bus Conductor at the
Transformer & Line feeders.
5 Attachments
Attachment-1: Calculation of Cantilever Strength of Bus Post Insulator supporting the Main Bus
Attachment-2: Calculation of Cantilever Strength of Bus Post Insulator supporting the Equipment
Bus at Coupling Bay
Attachment-3: Calculation of Cantilever Strength of Bus Post Insulator supporting the Equipment
Bus at Transformer & OHL Feeders.
6 Conclusion
1. The required Cantilever Strength of the C12.5-1550 for supporting the maximum bus span(24 m)
of the Main Bus is 995.67 daN, whereas the cantilever strength published by the manufacturer is
1250 daN. Thus the design is safe and Bus Post Insulators of C12.5-1550 type may be used for
supporting the Main Bus conductor.
2. The required Cantilever Strength of the C6-1550 for supporting the maximum bus span(12 m) of
the Equipment Bus at Coupling Bay is 281.23 daN, whereas the cantilever strength published by
(4)-G77700-S0019-L061-A
the manufacturer is 600 daN. Thus the design is safe and Bus Post Insulators of C6-1550 type
may be used for supporting the Equipment Bus conductor at the Coupling Bay.
3. The required Cantilever Strength of the C6-1550 for supporting the maximum bus span (12 m)
of the Equipment Bus at Transformer & OHL Feeders is 249.28 daN, whereas the cantilever
strength published by the manufacturer is 600 daN. Thus the design is safe and Bus Post Insula-
tors of C6-1550 type may be used for supporting the Equipment Bus conductor at Transformer &
OHL Feeders.
7 References
1. IEEE Std 605 : 1987 IEEE Guide for Design of Substation Rigid-Bus Structures.
2. Technical Data sheet for Aluminum Alloy Tubular Conductor: Manufacturer – Corus.
3. Technical Data sheet for Bus Post Insulator: Manufacturer – Porzellanfabrik Frauenthal
Insulators.
(4)-G77700-S0019-L061-A
MESNET
S
IZALATORU MEKANIK HESAPLAR (4)-G77700-S0019-L062-A
ATTACHMENT-1
CALCULATION OF CANTILEVER STRENGTH OF BUS POST INSULATOR SUPPORTING THE MAIN BUS
SYSTEM VOLTAGE ( IN KV. ): 400

FAULT LEVEL( IK3 ) ( IN KA.): 31.5
TUBULAR BUS CONDUCTOR :

a) Size : AlMgSi0.5F25
b) Outer dia. 250 mm
c) Thickness : 6 mm
d) Weight 12.4 Kg/m
e) conductor Young's
Modulus 7.00E+10 N/m2
f) Conductor spacing 6 m
g) Max Allowable stress 115 N/mm2
2
11.72 Kg/mm
h) Max. Span 24 m
i) Weight of Damper Material 3.66 Kg/m (Twin 954 CARDINAL ACSR Conductor)
INSULATOR DATA (Type:C12,5-1550):

a. Height 3.35 m
b. Max. Width 0.36 m
c. Min. Width 0.16 m
d Bus Cen. Line
height above Insulator 0.215 m
e. Weight 400 Kg
Max. Wind Pressure(Pmax) = 700 N/m2 (as per technical specification)

3
Ambient air density(d) = 0.613 Kg/m
1/2
Wind Velocity(V) = (Pmax/d) m/s
= 33.79 m/s
Now,
Coss sectional moment of inertia of the tube (J) = = ( S/64 ).(Do4 - Di4)
where,
DO = Outer Diameter of Conductor = 250 mm
Di = Inner Diameter of Tube = 238 mm
Therefore, J = 34231262.64 mm4
= 82.24027953 in4
3
Sectional Modulus of the tube S = J/(DO/2) mm
3
= 273850.1011 mm
= 16.71125822 in3
Calculation for conductor Wind Force:
-4 2
Conductor Wind Force (FW) = 2.132 x 10 CDKZGFV (DO+2r1) lbf/ft (Cl. 10. of IEEE:605)
Where
DO = Outer Diameter of Conductor 9.84 inch
r1 = Radial Ice thickness. = 0 inch
CD = Drag coefficient (Ref. Table 1 of IEEE:605) = 1 (For Round
conductor)
KZ = Height and exposure factor (Cl. 10.2 of IEEE:605) = 1
GF = Gust factor (Cl. 10.3 of IEEE:605) = 1.3

V =Wind speed at 30ft. above ground = 33.79 m/s
= 75.59 mi/h
Hence, FW = 15.59 lbf/ft
Calculation for Short Circuit Current Unit Force:
2 7
Short Circuit Current Unit Force (FSC) = 27.6* ISC /10 (D) lbf/ft
Gilgel Gibe II Hydroelectric Project

Page 1 OF 3
S (4)-G77700-S0019-L062-A
ATTACHMENT-1
ISC = Symmettrical short circuit current = 31500 A

D = Conductor spacing centre to centre = 236.22 inch
* = Constant based on type of short circuit and = 0.866
conductor location (Ref. Table 2 of IEEE:605)
Hence, FSC = 10.04 lbf/ft
Calculation for Gravitational Force:
Total bus unit weight (FG) = FC + FI + FD lbf/ft
FC = Conductor unit weight = 8.33 lbf/ft

FD = Damping material unit weight = 2.46 lbf/ft
FI = Ice Unit weight = 0 lbf/ft
Hence, FG = 10.79 lbf/ft
Calculation for Insulator Strength
a. Calculation for Bus Short circuit Current Force:
FSB = LE.FSC lbf
FSB = Bus Short Circuit Force transmitted to bus support fitting

LE = Effective Bus span length = 78.74 ft
FSC = Short Circuit Current Unit Force = 10.04 lbf/ft
Now, for a Rigid Bus Section of Equipment connection in a typical Line bay
across the Main Bus (as shown in the figure alongside) P P P
LE = 1/2(L1+L2) (Refer Table 5 of IEEE-605)
= 78.74016 ft
Adjescent Bus Span (L1) = 24 m
= 78.74 ft
= 78.74 ft 24m 24m
Therefore FSB = 790.55 lbf BPI BPI BPI
L1 L2
b. Calculation for Bus Wind Force : Fig 1
FWB = LE.FW lbf
Where,
FWB = Bus Wind force transmitted to bus support fitting
FW = Wind unit force on the bus = 15.59 lbf/ft
Therefore FWB = 1227.38 lbf
c. Calculation for Insulator wind force:
-5 2
FWI = 1.776 x 10 CDKZGFV (Di+2r1)Hi lbf
Where,
FWI = Wind Force on Insulator
Hi = Insulator Height = 131.89 Inch
Di = Effective insulator diameter
= (D1+D2)/2 = 10.2362 inch
D1 = Max. Insulator Width = 14.1732 inch
D2 = Min. Insulator Width = 6.2992 inch

Page 2 OF 3
S (4)-G77700-S0019-L062-A
ATTACHMENT-1
r1 = Radial Ice thickness = 0 inch

CD = Drag coefficient = 1 (For 'round conductor' as per Table 1 of IEEE:605)
KZ = Height and exposure factor = 1 (as per Cl. 10.2 of IEEE:605)
GF = Gust factor = 1.3 (as per Cl. 10.3 of IEEE:605)
= 75.59 mi/h
Therefore FWI = 178.11 lbf
Calculation for Total Insulator Cantilever load
FIS = K1 [ FWI/2 + {(Hi+Hf)/Hi} FWB] + K2 [{(Hi+Hf)/Hi} FSB] lbf
FIS = Total Cantilever load acting at the end of Insulator

FWI = Wind force on the insulator in lbf = 178.11 lbf
FSB = Bus Short Circuit Force transmitted to bus support fitting = 790.55 lbf
FWB = Bus Wind force transmitted to bus support fitting = 1227.38 lbf
Hi = Insulator Height = 131.89 inch
Hf = Bus Cen. Height above Insulator = 8.46 inch
K1 = Overload Factor applied to wind force = 1
K2 = Overload Factor applied to short circuit force = 1
Therefore FIS = 2236.49 lbf

Now
Effective weight of bus transmitted to bus support fitting
FGB = LE.FG lbf
where,
FG = Total Bus Unit Weight = 10.79 lbf/ft
Therefore FGB = 849.83 lbf
Natural Frequency of the Insulator with effective weight of the conductor span :
fi = (1/2S) [Ki g / (0.226FGI + FGB)]1/2
where,
Ki = Insulator cantilever Spring Constant = 1 lbf/inch
2
g = gravitional constant = 386 inch/s
FGI = Weight of the insulator = 881.85 lbf
FGB = Effective weight of bus transmitted to bus support fitting = 849.83 lbf
Therefore fi = 0.10 Hz
As fi < 50Hz => K2 = 1 (Refer Cl. No. 13.2 of IEEE: 605)
Cantilever Load on the Support Insulator FIS (Eqp) = 1015.37 Kgf

(in the direction of the Equipment Connection)
=> Reqiured cantilever Strength of the Supporting Insulator = 995.67 daN

Page 3 OF 3
S (4)-G77700-S0019-L061-A
ATTACHMENT-2
CALCULATION OF CANTILEVER STRENGTH OF BUS POST INSULATOR SUPPORTING THE EQUIPMENT BUS
AT COUPLING BAY


c) Thickness : 8 mm
d) Weight 7.6 Kg/m
f) Conductor spacing 6.5 m
2
11.72 Kg/mm
h) Max. Span 12 m
i) Weight of Damper Material 1.83 Kg/m (Single 954 CARDINAL ACSR Conductor)
INSULATOR DATA (Type:C6-1550):

a. Height 3.35 m
d Bus Cen. Line
e. Weight 291 Kg
2
Max. Wind Pressure(Pmax) = 700 N/m (as per technical specification)
3
1/2
= 33.79 m/s
Now,
( S/64 ).(Do - Di )
4 4
Coss sectional moment of inertia of the tube (J) = =
where,
= 10.6525978 in4
3
= 73899.69067 mm3
= 4.509608754 in3
Conductor Wind Force (FW) = 2.132 x 10-4 CDKZGFV2 (DO+2r1) lbf/ft (Cl. 10. of IEEE:605)
Where
conductor)

= 75.59 mi/h
Short Circuit Current Unit Force (FSC) = 27.6* ISC2 /107(D) lbf/ft

Page 1 OF 3
S (4)-G77700-S0019-L061-A
ATTACHMENT-2


FSB = LE.FSC lbf

Now, for a Rigid Bus Section of Equipment connection in a typical Line bay
across the Equipment Bus in Coupling bay(as shown in the figure alongside) F P P
LE = 1/8(3L1+4L2) (Refer Table 5 of IEEE-605)
= 31.98819 ft
= 39.37 ft
Adjescent Bus Span (L2) = 10.5 m
= 34.45 ft 12m 10.5m
Therefore FSB = 296.45 lbf ISO(Panto) BPI CT
L1 L2
FWB = LE.FW lbf
Where,
-5 2
Where,
= (D1+D2)/2 = 8.2677 inch

Page 2 OF 3
S (4)-G77700-S0019-L061-A
ATTACHMENT-2

KZ = Height and exposure factor = 1 (as per Cl. 10.2 of IEEE:605)
GF = Gust factor = 1.3 (as per Cl. 10.3 of IEEE:605)
= 75.59 mi/h


Now
FGB = LE.FG lbf
where,
fi = (1/2S) [Ki g / (0.226FGI + FGB)]1/2
where,
2


Page 3 OF 3
S (4)-G77700-S0019-L061-A
ATTACHMENT-3
CALCULATION OF CANTILEVER STRENGTH OF BUS POST INSULATOR SUPPORTING THE EQUIPMENT BUS
AT TRANSFORMER & OHL BAY


c) Thickness : 6 mm
d) Weight 5.8 Kg/m
f) Conductor spacing 6.5 m
2
11.72 Kg/mm
h) Max. Span 12 m
i) Weight of Damper Material 1.83 Kg/m (Single 954 CARDINAL ACSR Conductor)
INSULATOR DATA (Type:C6-1550):

a. Height 3.35 m
d Bus Cen. Line
e. Weight 291 Kg
2
Max. Wind Pressure(Pmax) = 700 N/m (as per technical specification)
3
1/2
= 33.79 m/s
Now,
( S/64 ).(Do - Di )
4 4
Coss sectional moment of inertia of the tube (J) = =
where,
= 8.405595626 in4
3
= 58311.684 mm3
= 3.558375932 in3
Conductor Wind Force (FW) = 2.132 x 10-4 CDKZGFV2 (DO+2r1) lbf/ft (Cl. 10. of IEEE:605)
Where
conductor)

= 75.59 mi/h
Short Circuit Current Unit Force (FSC) = 27.6* ISC2 /107(D) lbf/ft

Page 1 OF 3
S (4)-G77700-S0019-L061-A
ATTACHMENT-3


FSB = LE.FSC lbf

Now, for a Rigid Bus Section of Equipment connection in a typical Line bay across
the Equipment Bus in Transformer & OHL bay(as shown in the figure alongside) F P P P
LE = 1/8(3L1+4L2) (Refer Table 5 of IEEE-605)
= 27.88714 ft 8m
= 39.37 ft
Adjescent Bus Span (L2) = 8m
= 26.25 ft 12m 10.5m
Therefore FSB = 258.45 lbf ISO(Panto) BPI CB
L1 L2
FWB = LE.FW lbf
Where,
-5 2
Where,
= (D1+D2)/2 = 8.2677 inch

Page 2 OF 3
S (4)-G77700-S0019-L061-A
ATTACHMENT-3

KZ = Height and exposure factor = 1 (As per Cl. 10.2 of IEEE:605)
GF = Gust factor = 1.3 (As per Cl. 10.3 of IEEE:605)
= 75.59 mi/h


Now
FGB = LE.FG lbf
where,
fi = (1/2S) [Ki g / (0.226FGI + FGB)]1/2
where,
2


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400kV Switchyard Calculations

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Gilgel Gibe – II PROJECT

3. Conductor Data ................................................................................................................. 4

4. Bus Post Insulator data ..................................................................................................... 5

The principal forces on the bus post insulator are as follows –

a. Short circuit current force on the bus conductor.

b. Wind force on the bus conductor.

c. Wind force on the insulator stack.

Nominal System Voltage 400 kV

Short Circuit Fault Current 31.5 kA

Duration of Fault Current 1 sec

Maximum Wind Pressure 700 N/m2

Altitude above sea level >1500 m

i) 250/6mm Aluminum Tube (AlMgSi0.5F25)

Outer Diameter 250 mm

Weight 12.4 Kg/m

ii) 120/8mm Aluminum Tube (AlMgSi0.5F25)

Outer Diameter 120 mm

Weight 7.6 Kg/m

iii) 120/6mm Aluminum Tube (AlMgSi0.5F25)

Outer Diameter 120 mm

Weight 5.8 Kg/m

Common for all tubes specified above

Young’s Modulus 70000 N/mm2

4 Bus Post Insulator data

Height of Insulator Stack 3350 mm

Maximum Width 310 mm

Minimum Width 140 mm

Weight of Insulator 349 Kg

Cantilever Strength (designated by manufacturer) 800 daN

Height of Insulator Stack 3350 mm

Maximum Width 290 mm

Minimum Width 130 mm

Weight of Insulator 291 Kg

Cantilever Strength (designated by manufacturer) 600 daN

Height of Insulator Stack 3350 mm

Maximum Width 360 mm

Minimum Width 160 mm

Weight of Insulator 400 Kg

Cantilever Strength (designated by manufacturer) 1250 daN

x 250/6 mm AlMgSi0.5F25 Tubular Bus bar to serve as Main Bus Conductor.

SYSTEM VOLTAGE ( IN KV. ): 400

TUBULAR BUS CONDUCTOR :

INSULATOR DATA (Type:C12,5-1550):

Max. Wind Pressure(Pmax) = 700 N/m2 (as per technical specification)

Calculation for conductor Wind Force:

GF = Gust factor (Cl. 10.3 of IEEE:605) = 1.3

Calculation for Short Circuit Current Unit Force:

Gilgel Gibe II Hydroelectric Project

ISC = Symmettrical short circuit current = 31500 A

Hence, FSC = 10.04 lbf/ft

Calculation for Gravitational Force:

Total bus unit weight (FG) = FC + FI + FD lbf/ft

FC = Conductor unit weight = 8.33 lbf/ft

Hence, FG = 10.79 lbf/ft

Calculation for Insulator Strength

a. Calculation for Bus Short circuit Current Force:

FSB = LE.FSC lbf

FSB = Bus Short Circuit Force transmitted to bus support fitting

FWB = LE.FW lbf

Therefore FWB = 1227.38 lbf

c. Calculation for Insulator wind force:

Gilgel Gibe II Hydroelectric Project