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Energy Division

High Voltage Products for cables, substations and transmissions up to 800 kV Catalogue 2008

Content General 3

Cable Accessories up to 170 kV Experience, Certicates, References Terminations Joints Connection Boxes Installation & Tools

Equipment for Substations up to 800 kV Surge Arrester High Voltage Connection System (HVCS)

46

Equipment for Transmission up to 500 kV Tension Insulators Hardware for Transmission Lines Hardware for Distribution Lines

80

General

Energy Division
The Energy Division is a part of Tyco Electronics. The headquarter of the Energy Division is based in Ottobrunn, near Munich in Germany. The worldwide activities in the Energy Division will be handled from here. Besides modern laboratories for Research and Development the production of heat shrink tubings is placed here also the logistic centre for shipments into the whole world. In other countries like United Kingdom and France we have factories for producing the products which will be shown in this catalogue.

Quality and Environment


Quality The Tyco Electronics factories are certied to ISO 9000. Our vendor routine tests and internal incoming inspection conrm performance of all critical components used in the assembly of our products. We offer competitive lead times on all standard products. Environment The Tyco Electronics factories are also certied to ISO 14001. The gentle exposure with natural resources for our products and processes is for us one of the important aspects. Packaging We try to minimize the packaging materials, without any danger for the products. All packaging materials can be disposed without any problems. Recycling The most waste of the different locations will be recycled. If possible this will be done at the location or the waste will be repatriate to the economic cycle in another kind.

Test Procedure and Qualication


Tyco Electronics products are tested and certied to the major national and international standards, e. g. IEC, CENELEC, VDE, GOST, BS, etc.

Germany

Production Processes Our production processes are arranged to minimize the inuence of the environment. Hereby is the focus on an optimal Energy usage one of the main aspects. With special procedures we use the dispensed warmness from the production machinery to heat the production halls. Water We could reduce the usage of water by concurrent rising of the production volume. Waste We could reduce the amount of waste by concurrent rising of the production volume.

France

United Kingdom

Cable Accessories

Cable Accessories Experience, Certicates, References Terminations Joints Connection Boxes Installation & Tools 6 8 24 32 38

Experience
Tyco Electronics Raychem GmbH is one of the World leaders on cable accessories production for voltages up to 170 kV. Our company is focused on development, manufacturing of cable accessories and execution of projects providing reliable operation of electric power systems. Application of Tyco Electronics Raychem GmbH cable accessories provides the increase of customers protability and competitive capacity due to high operational performance of our products. Many worlds leading enterprises apply our cable accessories which are developed for the long-term operation in most severe conditions of indoor and outdoor maintenance in any climatic zones and high pollution locations. Our products have a very high reliability index which warrants saving of customers capital outlays. We use an experience accumulated within more than 40 years in sphere of materials science, development of new technologies and intensive study of customers needs. We constantly improve production technology and quality of our products paying attention to customers increasing requests. Our products passed all relevant tests in independent test labs in order to comply with quality requests of International Standards like IEC, IEEE. Tyco Electronics Raychem GmbH offers a wide range of cable accessories. In this catalogue we present the range from 42 kV up to 170 kV: Outdoor / Indoor Terminations Switchgear terminations and transformer terminations with Corona Shield Joints for plastic insulated cables Inline or shield-break type joints Tyco Electronics Raychem GmbH has technical support centers where customers can get professional assistance. Our specialists are always ready to nd solutions for any specic issue of every enterprise.

Certicates
ISO 9000 series and ISO 14001 certications for almost all locations underline our continuing commitment to quality and the environment. The products are subjected to extensive testing from the time they enter our plants as raw material until they leave as nished products. Requalication testing is carried out on a regular basis with installed components.

References
Our company has realized thousands of projects all over the World including tropical zones, deserts, places behind polar circle and in high pollution industrial and coastal areas. List of countries where our company executed projects with HV cable accessories increases every month and some of them are listed below: Australia Austria Belgium Brazil Canada China Colombia Croatia Denmark Egypt Finland France Germany Greece Hong-Kong India Indonesia Iran Ireland Kenya Korea Lithuania Luxemburg Netherlands Norway Peru Philippines Portugal Russia Saudi Arabia Singapore Slovenia Spain Sweden Taiwan Thailand Ukraine United Arabic Emirates United Kingdom USA

Detailed list of projects quantity in each country and names of customers can be presented upon additional inquiry.

Terminations

Terminations from 42 kV up to 72 kV Application, Features Indoor Terminations Outdoor Terminations Terminations with long creepage Lugs for Terminations 10 11 11 11 12

Terminations up to 170 kV Outdoor, Composite, Dry plug-in Outdoor, Composite, Oil-lled Connectors for Outdoor Terminations Switchgear & Transformer, Dry plug-in Switchgear & Transformer, Oil-lled 14 16 18 20 22

Termination Systems for Polymeric Insulated Cables up to 72 kV

Application Raychems terminations up to 72 kV are suitable for all climates and environments, even severely polluted areas, and for all installation conditions, including top feed installation. The factory-engineered kits contain a proven termination system which saves space, facilitates installation and enhances system reliability. The special design of the termination, which incorporates pre-coated tracking resistant sealants that melt during the shrinking process, results in a reliable and lasting barrier against moisture and corrosion.

Features The slim, compound-free Raychem Terminations are suitable for indoor and outdoor use on all polymeric cables for voltages from 42 kV up to 72 kV. Easy installation Non-tracking, heat-shrinkable outer insulation Heat-shrinkable stress control sleeves Pre-coated track resistant sealant Water and corrosion resistant Light-weight components Isolated base plate for sectionalisation High reliability

10

Outdoor

Indoor

Major Design Elements Kit content: The kit contains a limited number of light-weight components with unlimited shelf life under normal storage conditions. The heat-shrinkable sleeves are extremely versatile, and accommodate a wide range of cable diameters. Four basic kits cover all cable sizes, permitting reduced inventories and efcient stocking policy. The lightweight of the components and limited volume of the kits facilitate safe and easy transportation and handling. All components are included in a single box. The set of pre-engineered components requires no special or expensive tools for installation. Installation involves a simple set of standard procedures with no soldering required. Neither does the termination require lling with oil or compound. Risk of leakage is avoided, and lling and topping-up time on the job site is saved. High Performance Material: Raychem terminations are made of a specially formulated material with excellent tracking and erosion resistance characteristics. Accelerated and natural weathering tests which have been carried out at Raychem facilities and independent test sites around the world have demonstrated that the terminations are UV and water resistant and perform reliably even when exposed to sudden temperature variations. A Tracking and Erosion Test as per ASTM D2303 showed no tracking. IEC 112 was also conducted with no erosion or tracking observed. Electrical Stress Control: Screened or shielded power cables require electrical stress control in order to reduce the electrical stresses at the end of the screen and at the termination surface to avoid partial discharge and surface corona under all service conditions. Corona or electrical discharge can ultimately destroy the cable insulation, causing premature failure. Raychems stress control sleeves have electrical properties that smooth out the electrical eld at the end of the cable. This is achieved by the unique resistive and capacitive properties of the heat-shrinkable materials. A Universal System: The material used in these terminations is suitable for all climates and environments. It is not susceptible to damage from transportation or vandalism. The termination has a discreet, low prole which allows it to blend into landscapes.

Controlled torque lug

Non-tracking heat-shrinkable outer insulation

Heat-shrinkable sheds

Heat-shrinkable stress-control sleeves

Stress-relief material

Solderless grounding accessory

High-voltage sealant

42 kV Indoor Outdoor Long Creepage Cable with metal tape or lead shield b b

52 kV b b b b

72 kV b b b b b b Cable with metal tape or lead shield

Cable with metal tape or lead shield

Cable with wire shield

Cable with wire shield

Cable with wire shield

11

Torque Controlled Lugs for Termination Systems up to 72 kV

Features Torque controlled shear off bolts

Benets fast and safe installation excellent electrical performance excellent mechanical performance easy installation with standard box spanner pre-engineered design for perfect t Cu and Al conductors up to 1200 mm2 Variety of different palms available Body made of tinned aluminium alloy

Application Range

Lugs

12

Cable lug with 1-hole palm (EPPA-052-X/Y) Dimension: L = 190 mm A = 100 mm B = 50 mm D = 18 mm E = 25 mm F = 64 mm

X Diameter over cable conductor Y Diameter over cable insulation

Cable lug with 2-hole palm (EPPA-051-X/Y) Dimension: L = 190 mm A = 100 mm B = 27.5 mm C = 45 mm D = 18 mm E = 25 mm F = 64 mm

X Diameter over cable conductor Y Diameter over cable insulation

Cable lug with rod Dimension: Rod 30 mm (EPPA-050-X/Y) L = 190 mm A = 100 mm F = 64 mm = 30 mm Rod 40 mm (EPPA-053-X/Y) L = 264 mm A = 125 mm F = 106 mm = 40 mm Rod 50 mm (EPPA-061-X/Y) L = 264 mm A = 125 mm F = 106 mm = 50 mm

X Diameter over cable conductor Y Diameter over cable insulation

Cable lug with 4-hole palm (NEMA pad) (EPPA-054-X/Y)

Dimension: Contact plate 100 mm x 100 mm L = 232 mm D = 14.5 mm A = 100 mm E = 25 mm B = 27.5 mm F = 112 mm C = 45 mm Contact plate 80 mm x 80 mm L = 212 mm D = 14.5 mm A = 80 mm E = 25 mm B = 17.5 mm F = 112 mm C = 45 mm

X Diameter over cable conductor Y Diameter over cable insulation

13

Dry Self-Supporting Outdoor Termination OHVT up to 145 kV

Application The dry self-supporting termination is designed for voltage classes up to 145 kV and operation under severe environmental conditions. It is free from any insulating liquid or gel. Polymeric insulated cables of various designs can be adopted with respect to shielding and metal sheath. The polymeric housing with long creepage length covers extreme pollution levels according to IEC 60071-1 1996, IEC 60071-2 1996 and IEEE-1313.1-1996. Its mechanical performance is similar to conventional oil-lled terminations with composite housing. The termination is easily separable and consists of a plug-in part and an epoxy resin insulator protected with directly moulded silicone shed housing. Due to the short cable cutback dimensions of the plug-in the time required to install the termination is very short and can be further reduced in case of short cable links by pre-installing the plug-in on the shop oor. The plug-in is similar to the plug-in used with Tycos dry switchgear/ transformer termination.

Features Dry interface, no oil-lling Self-supporting Pre-fabricated and factory tested silicone rubber stress control Torque-controlled multi-contact conductor bolt Fast and simple installation combining GIS plug-in technology with polymeric insulators No special tools required to install the termination Isolated cable gland for sectionalisation Long creepage length Type tested according to IEC 60840

Technical Data OHVT-145D Highest Voltage UM Lightning Impulse Voltage Length Cantilever Force Flashover Distance Creepage Distance Pollution Level (IEC 60 137; 1995, VDE 0674, part 5) Weight approx. Max. Conductor Size Cu/Al approx. Outer Diameter Cable Insulation Outer Diameter Cable Oversheath kg mm
2

kV kV mm N mm mm

145 650 1750 5000 1320 4495 IV 130 1200 74 99

mm mm

14

Major Design Elements 1 The polymeric insulator (3) with embedded multi-contact electrode is attached to the support structure through the base plate (6) and the support insulators (7). The torque-controlled shear-off bolt connector (2) with multi contacts ts the cable conductor. The connector is suitable for stranded aluminium and copper conductors and can be modied to accept solid conductors as well. No special tool is required to install the connector. The silicone rubber stress cone (4) provides the electrical eld control and can easily be applied on the cable without tools owing to its excellent elasticity. A metal spring-loaded compression ring (5) presses the rubber stress cone into the specially shaped interior of the insulator housing, ensuring a uniform contact pressure and electrically sound interface. 2 3 4 The cable outer serving is adapted through a gland system (8), which addresses the individual shielding and armouring. The gland system also secures the cable.

6 7 8

1 Upper metal tting 2 Mechanical connector 3 Resin body with silicone shed housing 4 Stress cone 5 Spring-loaded compression ring 6 Base plate 7 Support insulators 8 Gland and sealing

15

Outdoor Composite Termination OHVT for 123 kV up to 170 kV

Application The termination is designed for voltage classes up to 170 kV and to operate under severe environmental conditions. Polymeric insulated cables of various designs can be adopted with respect to shielding and metal sheath. Composite housings with different creepage lengths up to 50 mm/kV are available covering the most common and also extreme pollution levels according to IEC 60071-1 1996, IEC 60071-2 1996 and IEEE-1313.1 1996.

Features Pressure-tight and light weight composite housing Pre-fabricated and factory tested Si-rubber stress cone Torque-controlled conductor bolt H/S components used for sealing No special tools required to install the termination Si-oil lling (lling from the top) Isolated base plate for sectionalisation Fittings made of corrosion resistant alloy Type tested according to IEC 60840 and IEEE 48 standards

Technical Data OHVT-145 Highest Voltage UM Lightning Impulse Voltage Length Diameter over sheds Cantilever Force Flashover Distance Creepage Distance Pollution Level (IEC 60 137; 1995, VDE 0674, part 5) Oil volume approx. Weight approx. Max. Conductor Size Cu/Al approx. Outer Diameter Cable Insulation Outer Diameter Cable Oversheath l kg mm
2

OHVT-170 170 750 2100 355 5000 on demand on demand IV 50 160 1200 108 119

kV kV mm mm N mm mm

145 650 1880 294 5000 on demand on demand II 35 120 1200 90 110

mm mm

16

1 2 3

Major Design Elements The pressure-tight composite housing (4) is made of a glass bre reinforced resin GFR tube with silicone rubber sheds moulded INSITU to the tube. The ttings (3) and the base plate (7) are made of non-corrosive alloy. To t the cable conductor, mechanical connectors with torque-controlled shear-off bolts (1) or crimp-type connectors are available. The connector is suitable for stranded aluminium and copper conductors and can be modied to accept solid conductors as well. No special tool is required to install the mechanical connector. Heat-shrinkable polymeric tubing containing oil-resistant sealant encapsulates the connector barrel and the polymeric insulation transition. The silicone rubber stress cone (6) provides the electrical eld control and can easily be applied without tools owing to its excellent elasticity. The interface between stress cone, cable insulation and inner GFR housing is lled with silicone oil (5) which could be easily lled from the top. The cable outer serving is adapted through a gland system (9), which addresses the individual shielding and armouring of the cable. Heat shrinkable tubing is used to seal the cable gland. Support insulators (8) are supplied for sectionalisation and cross-bonding, when separate grounding is required.

7 8 9

1 2 3 4 5 6 7 8 9

Connector (mechanical or crimp) Sealing system Upper Metal tting Composite housing Oil-lling Stress cone Base plate Support insulators Gland and sealing

17

Connectors for Outdoor Terminations up to 145 kV

Terminal Pad (NEMA)


C

Description ROD 30

D 2631 3641 4651

B 29 32 25

C 85 92 94

L 193 200 207

Reference SIML-0-0707021-1 SIML-0-0707121-1 SIML-0-0718671-1

ROD 40
16 L B

ROD 50 Dimensions in mm

14,3 D 44,4 100

44,4 27,8 100

Straight Rod
C C

Description ROD 30

D 2631 3641

B 84 92

C 85 102

L 180 195

Reference SIML-0-0706684-1 SIML-0-0706685-1

ROD 40 Dimensions in mm

Straight Transition Rod


C1 C2

Description ROD 30/20

D1 2631 2631 2631 3641 3641 3641 3641 4651 4651 4651 4651 4651

D2 1621 2126 3136 1621 2126 2631 3136 1621 2126 2631 3136 3641

B1 84 84 84 102 102 102 102 112 112 112 112 112

B2 66 66 84 66 66 84 84 66 66 84 84 102

C1 85 85 85 92 92 92 92 92 92 92 92 92

C2 70 70 85 70 70 85 85 70 70 85 85 92

L 165 165 180 172 172 187 187 174 174 189 189 196

Reference SIML-0-0706684-1 SIML-0-0706636-1 SIML-0-0706949-1 SIML-0-0706700-1 SIML-0-0706635-1 SIML-0-0706655-1 SIML-0-0706663-1 SIML-0-0712016-1 SIML-0-0716341-1 SIML-0-0711000-1 SIML-0-0711002-1 SIML-0-0711001-1

D1

D2

ROD 30/25 ROD 30/35

ROD 40/20 ROD 40/25 ROD 40/30

B1

D1

D2

B2

ROD 40/35 ROD 50/20 ROD 50/25 ROD 50/30 ROD 50/35 ROD 50/40

Dimensions in mm

18

T-Rod
C1 C2 D1

Description

D1

D2 1621 2126 2631 3136 3641 1621 2126 2631 3136 3641 1621 2126 2631 3136 3641

B1 84 84 84 84 84 92 92 92 92 92 94 94 94 94 94

B2 66 66 84 84 102 66 66 84 84 102 66 66 84 84 102

C1 124 124 140 140 143 131 131 146 146 151 135 135 151 151 158

C2 70 70 85 85 92 70 70 85 85 92 70 70 85 85 92

L 166 166 182 182 195 182 182 197 207 207 191 191 207 207 214

Reference SIML-0-0716192-1 SIML-0-0706686-1 SIML-0-0706627-1 SIML-0-0706638-1 SIML-0-0706667-1 SIML-0-0716198-1 SIML-0-0716106-1 SIML-0-0706624-1 SIML-0-0706623-1 SIML-0-0706622-1 SIML-0-0716203-1 SIML-0-0716342-1 SIML-0-0716342-1 SIML-0-0716204-1 SIML-0-0706664-1

T-ROD 30/20 2631


D2

T-ROD 30/25

2631

T-ROD 30/30 2631


D1

T-ROD 30/35

2631

T-ROD 30/40 2631


B1 D2 B2

T-ROD 40/20 3641 T-ROD 40/25 3641 T-ROD 40/30 3641

T-ROD 40/35 3641 T-ROD 40/40 3641 T-ROD 50/20 4651 T-ROD 50/25 4651 T-ROD 50/30 4651 T-ROD 50/35 4651 T-ROD 50/40 4651 Dimensions in mm

Twin Straight Rod


B1 B2 D2 D2 D2 C2

Description

D1

D2 3641 3136 3641

B1 184 184 207

B2 100 100 105

B3 112 122 112

C1 94 94 94

C2 85 85 85

L 214 214 230

Reference SIML-0-0716192-1 SIML-0-0706686-1 SIML-0-0706627-1

TWIN STRAIGHT 4651 ROD 50/30 TWIN STRAIGHT 4651 ROD 50/35
L

TWIN STRAIGHT 4651 ROD 50/40 Dimensions in mm

C1

D1 B3

D1

Twin T-Rod
B
D2 D2 D2

L1

Description TWIN T ROD 50/30 TWIN T ROD 50/35

D1 4651 4651 4651

D2

C1 136 136 145

C2 94 94 94

C3 134 134 145

C4 84 84 92

L1 185 185 186

L2 171 171 195

Reference SIML-0-0706684-1 SIML-0-0706636-1 SIML-0-0706949-1

3641 100 3136 100 3641 105

C1 C2 D1
D1

L2

TWIN T ROD 50/40

C4 C3

Dimensions in mm

19

Dry Compact Switchgear & Transformer Termination PHVS & PHVT from 72 kV up to 145 kV
Application The dry compact switchgear termination for voltage classes up to 145 kV is designed to be installed in cable entry housings of gas-insulated switchgear (GIS). It complies with IEC 62271-209 standard, which essentially species the interfaces between the termination and the switchgear. Therefore the termination will t into all GIS complying with IEC 62271-209. An adapter is available to match the dimensions of wet (oil-lled) type terminations, which are also specied in IEC 62271-209. The termination operates in SF6 but also in insulating liquids like transformer oil. A corona shield at the top of the termination then provides the necessary shielding of the terminal. The termination is easily separable and consists of a plug-in part and an epoxy resin insulator. The insulator can be installed by the GIS or transformer manufacturer already at the factory saving installation time onsite and reducing the risk of contamination of the cable entry housing. In case of short cable links and due to the short length and light weight of the plug-in part it can be also preinstalled by the cable manufacturer further reducing the time required to install a substation.

Features Dry interfaces, no oil-lling Dimensions comply with IEC 62271-209 Pressure-tight resin housing Operates in SF6 and insulating liquids Pre-fabricated and factory tested Si-rubber stress cone Torque-controlled multi-contact conductor bolt No special tools required to install the termination Isolated cable gland for sectionalisation Type tested according to IEC 60840 and IEC 62271-209 standards

Technical Data PHVS-145 Highest Voltage UM Lightning Impulse Voltage Length (with IEC Adapter) Weight approx. (with IEC Adapter) Operating Pressure SF6 Max. Conductor Size Cu/Al approx. (optional) Outer Diameter Cable Insulation Outer Diameter Cable Oversheath kV kV mm kg bar mm2 mm mm 145 650 470 (757) 38 (42) 26 800 (1200) 74 99 PHVT-145 145 650 470 (757) 38 (42) 800 (1200) 74 99

20

Major Design Elements The epoxy-resin insulator (4) with embedded multi-contact electrode forms the gas pressure-tight interface between GIS or transformer cable entry and the plug-in part of the termination. It is attached to the cable entry housing with the xing ring (7).

2 The torque-controlled shear-off bolt connector (3) with multi-contacts ts the cable conductor. The connector is suitable for stranded aluminium and copper conductors and can be modied to accept solid conductors as well. No special tool is required to install the connector. The silicone rubber stress cone (5) provides the electrical eld control and can easily be applied without tools owing to its excellent elasticity. A metal spring-loaded compression ring (6) presses the rubber stress cone into the specially shaped interior of the resin housing, ensuring a uniform contact pressure and electrically sound interface. A corona shield (1) can be easily attached to the termination for use in insulating liquids. Compared with IEC 60859 wider clearances apply in this application. The cable outer serving is adapted through a gland system (8), which addresses the individual shielding and armouring. The gland system also secures the cable. An adapter (2) can be used to match the dimensions of wet type switchgear and transformer terminations which makes the termination an ideal choice for replacing oil-lled terminations.

4 5 6 7

1 Corona Shield 2 Adapter (optional) 3 Connector (mechanical) 4 Resin housing 5 Stress cone 6 Spring-loaded compression ring 7 Fixing ring 8 Gland and sealing

62271-209)

62271-209)

21

Switchgear & Transformer Termination SHVT & THVT for 72 kV up to 170 kV

Application The switchgear termination for voltage classes up to 170 kV is designed to be installed in cable entry housings of gas-insulated switchgear (GIS). It complies with IEC 62271-209 and IEEE 1300 standards, which essentially specify the interfaces between the termination and the switchgear. Therefore the termination will t into all GIS complying with these standards. The termination operates in SF6 but also in insulating liquids like transformer oil. A corona shield at the top of the termination then provides the necessary shielding of the terminal.

Features Si-oil lling (no need for heating before lling) Dimensions comply with IEC 62271-209 and IEEE 1300 Pressure-tight resin housing Operates in SF6 and insulating liquids Pre-fabricated and factory tested Si-rubber stress cone Torque-controlled conductor bolt No special tools required to install the termination Isolated cable gland for sectionalisation Type tested according to IEC 60840, IEC 62271-209 and IEEE 1300 standards

Technical Data SHVT-170 Highest Voltage UM Lightning Impulse Voltage Length Cantilever Force Creepage Distance Oil volume approx. Weight approx. Operating Pressure SF6 Max. Conductor Size Cu/Al approx. Outer Diameter Cable Insulation Outer Diameter Cable Oversheath kV kV mm N mm l kg bar mm
2

THVT-170 170 750 757 6500 650 12 92 1200 84 105

170 750 757 6500 650 12 92 26 1200 84 105

mm mm

22

Major Design Elements The epoxy-resin insulator (3) with embedded electrode forms the gas pressure-tight interface between GIS or transformer cable entry and the oil-lled cable compartment of the termination. It is attached to the cable entry housing with the xing ring (6).

To t the cable conductor, torquecontrolled shear-off bolt connector (2) or crimp-type connectors are available. The connector is suitable for stranded aluminium and copper conductors and can be modied to accept solid conductors as well. No special tool is required to install the mechanical connector. The exible double sealing system is installerfriendly and ensures persistent leak tightness of the top assembly. Heat shrinkable polymeric tubing containing oil-resistant sealant encapsulates the connector barrel and the polymeric insulation transition. The silicone rubber stress cone (5) provides the electrical eld control and can easily be applied without tools owing to its excellent elasticity. The interface between stress cone, cable insulation and inner GFR housing is lled with silicone oil (4) through a lling nozzle at the base plate. The cable outer serving is adapted through a gland system (8), which addresses the individual shielding and armouring of the cable. Heat shrinkable tubing is used to seal the cable gland.

1 2 3 4 5 6 7 8

Corona shield (THVT only) Connector (mechanical or crimp) Resin housing Oil-lling Stress cone Fixing ring Base Plate Gland and sealing
62271-209)

62271-209)

23

24

Joints

Joints from 42 kV up to 72 kV Application, Features Connectors for Joints 26 29

Joints up to 170 kV Inline and Shield-Break Joints 30

25

Joints for Polymeric Insulated Cables EHVS from 42 kV up to 72 kV

Application The elastomeric Raychem joints from 42 kV up to 72 kV are suitable for all type of polymeric cables and can accommodate various cross-bonding shield break and external grounding arrangements.

Features Quick cable preparation. Simplied installation: No specialists required. A qualied medium-voltage jointer will be trained in one day. Pre-engineered wall thickness: All product dimensions are set and checked at the factory before the product is shipped to the eld. Time savings: Due to short installation time outages are kept to a minimum in repair situations. High reliability: The combination of long experience and rigorous testing to international standards leads to high joint reliability.

26

Major Design Elements Designed for easy jointing: The Raychem joint design comprises of a connector that allows even large cross-sections to be jointed and two dual-wall, heat-shrinkable sleeves. A heavy-walled co-extrusion of two layers of red insulation forms the inner sleeve. The outer sleeve consists of a thick layer of red insulation co-extruded under a black outer conductive layer which acts as the joint screen.

Kit Content: The set of pre-engineered components and the Raychem connector require no special installation tools. After placing the heat-shrinkable components over the cable end, the connector is installed by tightening the special bolts, which shear off cleanly when the correct contact force is reached. Each sleeve in turn is placed over the connector area and shrunk down. Copper shielding mesh and an adhesive-coated outer sleeve for water sealing then complete the joint.

Controlled-torque Connector: The connector design allows cables to be jointed without special tools, heat treatment as dressing/ling after installation. Shear-head bolts ensure a pre-engineered electrical connection. The shear-head bolts break off at a pre-determined level below the outer surface of the connector, at a dened torque. This ensures the correct contact pressure is reached every time. The stable voltage drop provided by this concept has been demonstrated in eld installations which closely follow the predictions of long-term load-cycling tests. Comprehensive qualication procedures like IEC 61238-1996 and ANSI 119.4 1993 prove the excellent longterm performance.

27

Cross-bonding / shield break: The use of heat-shrinkable sleeves for stress control, insulation, and screening provides a location for the shield break at the end of the joint.

Electrical Stress Control: A material with stress adjusting characteristics is applied onto the connector and cable screen ends. This heat-shrinkable sleeve incorporates a conductive coating in the connector area which equalizes potential in the manner of a Faraday cage. It extends over the dielectric to accommodate possible insulation shrink-back.

Elastomeric Technology: Two dual-wall, heatshrinkable elastomeric sleeves shrink rapidly and deliver pre-engineered, uniform layers of thick insulation. The outer layer shrink to the pre-determined diameter and the elastomeric inner part conrms tightly to the joint.

Outer Sealing: The cable oversheath is replaced with a thick-wall heat-shrinkable insulating sleeve, which provides the required dielectric strength and create an effective water seal and corrosion protection.

42 kV Joints b Cable with wire shield and cross bonding module b b

52 kV b Cable with wire shield and cross bonding module b

72 kV b Cable with wire shield and cross bonding module b

Cable with metal tape or lead shield and cross bonding module

Cable with metal tape or lead shield and cross bonding module

28

Cable with metal tape or lead shield and cross bonding module

Cable with metal tape or lead shield

Cable with metal tape or lead shield

Cable with metal tape or lead shield

Cable with wire shield

Cable with wire shield

Cable with wire shield

Torque Controlled Connectors for Joints up to 72 kV

Features Torque controlled shear off bolts fast and safe installation excellent electrical performance excellent mechanical performance easy installation with standard box spanner Application Range pre-engineered design for perfect t Cu and Al conductors Up to 1200 mm2

Connectors Straight and size transition type Body made of aluminium alloy

Mechanical connector for straight connection

(EPPA-047-X/Y-L)

Dimension: L = 130 mm L = 180 mm

X Diameter over cable conductor Y Diameter over cable insulation

Mechanical connector for size transition

(EPPA-047-X1/Y1-X2/Y2-L)

Dimension: L = 130 mm L = 180 mm

X1/X2 Diameter over cable conductor Y1/Y2 Diameter over cable insulation

Mechanical connector for cables with small insulation thickness

(EPPA-063-X1/Y1-X2/Y2-L)

Dimension: L = 180 mm L = 230 mm

X1/X2 Diameter over cable conductor Y1/Y2 Diameter over cable insulation

29

Inline and Shield-Break Joint EHVS for 123 kV up to 170 kV

Application The joint is a pre-fabricated threepiece design for voltages from 123 kV up to 170 kV. Polymeric insulated cables of various designs can be adopted with respect to shielding and metal sheath.

Features Pre-fabricated three-piece joint design Torque-controlled conductor sleeves Integrated moisture barrier using H/S components Short cut-back dimensions No special tools required to install the joint Can adapt shield-break applications Cable size transition is possible Factory tested Si-rubber parts Type tested according to IEC 60840 and IEEE 404 standards

Technical Data EHVS-145-IL Highest Voltage UM Lightning Impulse Voltage Length Diameter Weight approx. Max. Conductor Size Cu/Al approx. Outer Diameter Cable Insulation Outer Diameter Cable Oversheath IL: Inline Joint SB: Shield Break Joint kV kV mm mm kg mm2 mm mm 145 650 1500 195 40 1200 75 105 EHVS-170-IL 170 750 1900 240 60 1200 84 105 EHVS-145-SB 145 650 2000 195 45 1200 75 105 EHVS-170-SB 170 750 2400 245 75 1200 108 140

30

Major Design Elements The joint consists of connector (1), cable adapters (2) including stress cones and main joint body (3) containing Faraday cage (7) and outer serving by heat-shrink technology (9,12). The conductors of the cable are connected by a mechanical connector sleeve (1) using torque controlled shear-off bolts. The connector sleeve is suitable for stranded aluminium and copper conductors but can be easily modied to accept solid conductors as well. The Si-rubber cable adapters (2), accommodating the various cable insulation diameters, build up the connection area to an almost constant diameter. This allows to cover different cable cross-sections with just one main insulation joint body (3). Therefore cross-section transitions are possible without any extra components. No extra tooling is needed to push-on the Si-rubber cable adapters (2) and the Si-rubber joint main body (3) due to its excellent elasticity. A metal shielding clamp (7) on top of the connector ensures perfect heat transmission and a smooth interface t. The xing rings (6) keep the cable adapter and the cable dielectric in position. During the installation the main body is parked on the over sheath of the cable. This keeps the cut back length and cable preparation time as short as possible. Mechanical solderless connector technologies (8) are used to connect metal shields copper wires, metal sheath and CAS. Heat-shrink technologies (9,12) replace the cable serving and the moisture barrier. The joint concept is similar for the shield break joints, despite the shield continuity. Special sealant components make it possible to use double-insulated ground leads, and thereby to utilise the proven heat-shrink technology.

4 4 2 3 5 6 1 7 7 9 9 10 11 12 12 10 11 2 3 5 6 1

1 2 3 4 5 6 7 8 9 10 11 12

Mechanical connector Adapter Main body Stress cone HV electrode Fixing ring Metal shielding clamp Solderless shield connection Conductive tubing Copper mesh Insulating tubing Outer protection with integrated moisture barrier

EHVS-SB (Shield Break Joint)

EHVS-IL (Inline Joint)

31

32

Connection Boxes

Connection Boxes Link Boxes Add-on Kits for 145 kV Cable Accessories 34 37

33

Link Boxes Cross bonding and sectionalisation for high-voltage cable systems
Application Single point bonding Mid point grounding Direct grounding Grounding through SVL Cross bonding and transposition

Features Compact design Stainless steel Hermetically sealed 1-phase and 3-phase boxes Sheath voltage limiters (SVL) IP65 / IP 68 Removable links For coaxial cable or single core cable Voltage withstand according to IEC 60840 Annex H

34

Link boxes and sheath voltage limiters Link boxes are used with cable joints and terminations to provide easy access to the screen of HV cables for testing purposes and to reduce induced voltages building up the sheath due to load and short circuit currents. Lightning and switching operations may cause transient over voltages on the cable sheath. Sheath voltage limiters (surge arresters) may be integrated into the link boxes in order to limit these over voltages. Depending on the application different link boxes are available.

Mechanical design Made of stainless steel 1-phase and 3-phase link boxes With and without SVL Coaxial cables entry or single core cable entry Removable links Compact design available (no removable links) Hermetically sealed Tight up to a water level of 5 m Lugs and bonding cables sealed inside and outside the link box with heat shrink tubes coated with hot melt adhesive Suitable for Single point bonding Mid point grounding Direct grounding Grounding through SVL Cross bonding and transposition

Electrical design Cross section of links up to 300 mm2 Uc = 3 kV of 6 kV SVL Short circuit current withstand 1 s 31.5 kA BIL phase to ground / phase to phase 40 kV

Application Installation in pits or vaults and on structures or poles

35

Available Link Boxes Description HVLB-GND-0/4-41-1PH-4WAY Comment 1-Phase Link Box for Direct Grounding Assembly (4WAY) 1-Phase Link Box with 1 kV SVL Assembly (6WAY) 1-Phase Link Box with 6 kV SVL Assembly (4WAY) Dimensions LxWxH (mm) 496x862x320 Special properties 4 cable entries, IP68, 3 mm stainless steel, removable links, 300 mm2 tinned copper links, BIL 40 kV, short circuit current 31.5 kA/1 s 6 cable entries, 1 kV SVL, compact design, no removable links, stainless steel 4 cable entries, IP68, 3 mm stainless steel, removable links, 300 mm2 tinned copper links, 6 kV SVL, BIL 40 kV, short circuit current 31.5 kA/1 s IP 68, 3 mm stainless steel, removable links, 300 mm2 tinned copper links, 6 kV SVL, BIL 40 kV, short circuit current 31.5 kA/1 s 1 kV SVL, compact design, no removable links, stainless steel removable links, 240 mm2 tinned copper links, 6 kV SVL, stainless steel, compact design IP 68, 3 mm stainless steel, removable links, 300 mm2 tinned copper links, 6 kV SVL, BIL 40 kV, short circuit current 31.5 kA/1 s coaxial cable entry, IP 68, 3 mm stainless steel, removable links, 300 mm2 tinned copper links, BIL 40 kV, short circuit current 31.5 kA/1 s coaxial cable entry, IP 68, 3 mm stainless steel, removable links, 300 mm2 tinned copper links, 6 kV SVL, BIL 40 kV, short circuit current 31.5 kA/1 s compact design, no removable links 3 kV SVL, compact design, no removable links 6 kV SVL, compact design, no removable links compact design, no removable links 3 kV SVL, compact design, no removable links 6 kV SVL, compact design, no removable links

HVLB-GND-1/6

340x725x293

HVLB-GND-6/4-41-1PH-4WAY

496x862x320

HVLB-GND-0/4-41-3PH

3-Phase Link Box for Direct Grounding Assembly

469x725x320

HVLB-GND-1/3 HVLB-GND-6/3

3-Phase Link Box with 1 kV SVL Assembly 3-Phase Link Box with 6 kV SVL Assembly 3-Phase Link Box with 6 kV SVL Assembly

310x310x255 310x310x255

HVLB-GND-6/4-41-3PH

496x725x320

HVLB-CRB-0/3-50-3PH

3-Phase Link Box Cross Bonding for Direct Grounding Assembly

355x883x621

HVLB-CRB-6/3-50-3PH

3-Phase Link Box Cross Bonding with 6 kV SVL Assembly

355x883x621

EPPA-055-0/1 EPPA-055-3/1 EPPA-055-6/1 EPPA-055-0/3 EPPA-055-3/3 EPPA-055-6/3

1-Phase Link Box for Direct Grounding Assembly 1-Phase Link Box with 3 kV SVL Assembly 1-Phase Link Box with 6 kV SVL Assembly 3-Phase Link Box for Direct Grounding Assembly 3-Phase Link Box with 3 kV SVL Assembly 3-Phase Link Box with 6 kV SVL Assembly

300x190x165 300x190x165 300x190x165 310x310x255 310x310x255 310x310x255

36

Add-on Kits for 145 kV Cable Accessories

Application: Add-on kits for HV cables with integrated glass bres are available for all Raychem 145 kV terminations and joints. The add-on kits include all required components to reliably seal the cable and the glass bre outlet as well as suitable tubes to protect the sensitive steel pipes carrying the glass bres. The standard kit can be used for cables with up to two individual steel pipes. Glass bre splicing kits may be included in the add-on kits as well. These kits are able to handle up to 12 individual glass bres per steel pipe. The commonly used FOSC 500 splicing kit is able to take two steel pipes so up to 24 glass bres can be spliced with this splice box. The box is isolated and is therefore suitable for cross bonding joints as well. The glass bre outlet is arranged straight, which means the pipe doesnt need to be fold back. This saves the pipe from being snapped off because its smallest permitted bending radius usually is bigger than the diameter of the power cable. For more details please contact your relevant Sales Representative.

37

38

Installation & Tools

Installation & Tools Installation, Training and Supervision Installation Requirements Toolbox for the installation of HV Cable Accessories 40 41

45

39

Installation, Training and Supervision

Tyco Electronics Raychem is an independent supplier of HV cable accessories. We provide our products world wide to utilities having their own installation crews contractors providing installation services to utilities and industrial customers cable manufacturers We are able to offer following services: Installations (accessories only) Trainings (on-site and in-house) Supervisions Installations Tyco Electronics has got well trained and experienced jointers which are able to carry out installation at construction sites. Usually they are supported by local helpers provided by the contractor or the local utility. In case there are no trained jointers available locally ordering installation services from us is the rst choice. Training Jointers with 5 years or more experience in HV cable preparation may be trained on-site during an installation. Less experience jointers should be rst trained in our labs. In both cases well experienced supervisors demonstrate how to install our products in order to ensure the high performance expected to be enjoyed over the whole life time of our products. At the end of the training the jointers will be able to carry out installations without or at least with a minimum of help provided by our supervisors. Supervision Jointers, which have been trained by Tyco Electronics supervisors prior to an installation but havent yet got sufcient on-site experience in installing Tyco Electronics accessories, may need the help of a supervisor on-site. We recommend ordering this service for the rst installations. If ensures that all accessories are installed according to the instructions provided with the accessories.

For the installation of the cable accessories the construction side must be prepared before. The installation requirements for the different products are described on the following pages. 40

Installation Requirements

General
Cable accessories from Tyco Electronics Raychem GmbH are very reliable in service and offer a long maintenancefree life cycle. In order to assure both the installation has to be carried out as described in our installation instruction. In addition to the process steps described in our installation instructions we recommend following commonly accepted installation practice.

Joints EHVS
Minimum requirements for the installation Access to installation site for motor vehicles / lorries. Complete readiness of cable routing. Joints may be directly buried (i.e. in a concrete tray) or installed in man holes. The size of the concrete tray or the man hole should be 4 m x 10 m in order to allow the joints to be staggered. In case the joints are to be installed in-plane then size may be reduced to 3 m x 5 m Cables to be jointed shall overlap by at least 2 m. Please consult the relevant installation instruction for details. Temporary electric lighting at the installation place (spot lights and uorescent lamps) Free power sockets 230 V, min. 10 A Ambient temperature at installation place shall be 15C min. In case of lower ambient temperature, gas or electric heaters are required. Two or more helpers per installation team Taking into account the technical complexity of accessories and their installation procedure we strongly recommend installations to be carried out and supervised by well trained and qualied installers only.

Cable laying and jointing in a concrete duct.

EHVS Installation The sketch besides shows an example for a concrete shelter in which the joints have been staggered. The cable is laid in a cable ducts installed on metal poles of several meters height

41

A similar arrangement to the sketch on the previous page is shown below.

Due to the limited space and two systems to be jointed, the shelter has got two stories.

The following sketch shows the top view of the two previous arrangements. The cables however are arranged in an underground cable duct.

Terminations OHVT
Minimum requirements for the installation Access to installation site for motor vehicles / lorries. Complete readiness of cable routing including xing the cable to the termination platform. Depending on the dimension of the termination to be installed the cable end shall project above the termination base plate by 23 meters. Temporary electric lighting at the installation place (spot lights and uorescent lamps) Free power sockets 230 V, min. 10 A Ambient temperature at installation place shall be 15C min. In case of lower ambient temperature, gas or electric heaters are required. Two or more helpers per installation team. Taking into account the technical complexity of accessories and their installation procedure we strongly recommend installations to be carried out and supervised by well trained and qualied installers only. Platforms (permanent): Platforms have to be strong, tough and rigid enough to withstand all expected mechanical loads taking into consideration the weight of the terminations, dynamic forces caused by short circuit currents, wind loads, icing etc. and temporary loads like those taking effect during installations. The support structure shall be equipped with a sufcient number of non-metallic cable cleats xing the cable to the support structure. Spacing between the cable cleats shall be coordinated with the cable manufacturer. The max. distance between the termination gland and the nearest cable cleat shall not exceed 1 m. The platform, to which the individual base plate of the termination is assembled to, shall be level and preferably horizontal. The mounting holes for the base plate shall be as per provided offer drawings. In case the platform is more than 3 m above ground we recommend contacting your relevant Sales Representative to provide you with additional details. Scaffolding (temporary): The use of scaffolding is strongly recommended. It shall be equipped with fences, handrails, stairs or rm ladders and shall follow common safety rules. The roof ridge shall be solid enough to carry a load of approx. 100 kg (composite insulator). The scaffolding shall have 2 levels. The lower level shall be approx. 700 mm below the terminations base plate, the upper level approx. 2 m above the lower one. The oors may be prepared using wooden planks or steel grids and shall be able to carry min. 250 kg/m2. Depending on weather conditions the scaffolding may require to be protected from the elements with a tent or tarpaulin. The clearance between the top oor and the roof ridge shall be in the range of 3.0 m. The tarpaulin should be easy to remove to allow the insulator to be lifted over the prepared cable easily. The recommended size of the scaffolding is 4 m x 4 m with the termination in the center. In case the terminations are installed side by side the size shall be 8 m x 4 m.

42

OHVT platforms and scaffolding The sketch below shows an example for a platform including the scaffolding for 3 terminations assembled side by side. Special actions may have to be taken in case the vertical cable span exceeds 3 m. The cable may require more and/or special cable cleats to x the cable reliably. Features: Weight-bearing capacity: 250 kg/m2 Lifting capacity of block and tackle: max. 5000 N Weatherproof covering (transparent tarpaulin) from the roof ridge down to the upper level (summer) Weatherproof covering (transparent tarpaulin) from the roof ridge down to the bottom level (winter)

Chain block

2. platform

Sealing End

1. platform

Power Cable Cable Support Protection Pipe

OHVT Mounting The terminations base plate shall be mounted on a horizontal steel structure similar to the one shown in the sketch beside:

43

OHVT Installation with Surge Arrester Similar platforms can be used for both, outdoor terminations and surge arresters installed together. The clearance between termination and arrester has to follow local regulations. By default it should be 1500 mm. Surge Arresters are shown in a separate chapter of this catalogue.

Switchgear & Transformer terminations SHVT, THVT, PHVS, PHVT


Minimum requirements for the installation Access to installation site for motor vehicles / lorries. Forklift Complete readiness of cable routing including xing the cable to vertical cable duct (if any). The cable end shall project above the lower cover of the cable entry box by 1 meter. Cable ducts underneath the opening in the ceiling/oor for the cable shall be xed temporarily only because the cables have to be pulled back by up to 3 meters for cable preparation. Temporary electric lighting at the installation place (spot lights and uorescent lamps) Free power sockets 230 V, min. 10 A Ambient temperature at installation place shall be 15C min. In case of lower ambient temperature, gas or electric heaters are required. Two or more helpers per installation team. Taking into account the technical complexity of accessories and their installation procedure we strongly recommend installations to be carried out and supervised by well trained and qualied installers only. For questions please contact your relevant Sales representative.

44

Toolbox for the installation of HV Cable Accessories

For the installation of the HV Cable accessories we recommend using our toolbox equipped with about 70 different tools (see right column). (Cable stripping tool and straightening set tool have to be ordered separately, available as an extension set as well) For details on how to use the tools during installation please contact your Sales Representative and ask for a price quotation on training/supervision.

List of Standard Tools and Auxiliary Materials: Cable Saw with Blade Small Sanding Machine Big Sanding Machine Extension Cable Drum Cordless Impact Wrench Drill Machine Set of Fork/Ring Spanners Set of Hexagon Spanners Big Screw Clamp Small Screw Clamp Pinch Bar Big Box Spanner Assembly Small Box Spanner Assembly Big Sliding Caliper Torque Wrench Set of Files Small Sliding Caliper Wood Rasp Set of Dowel Pin Fasteners Big Hammer Small Hammer Club Hammer Plastic Hammer Set of Screw drivers Engineers pliers Edge Cutter Pincers Set of Ring Spanner Halogen Radiator Plastic Tarpaulin Pressing Tool Crane Rope Spirit Level Pipe Cutter Adjustable Wrench Set of Eyelet Pliers Chain Host Metal Saw Set of Drills to unscrew Bolts Set of White Marker Pens Tape Ruler Hook Knife Jacket Removal Tool Carton Abrasive Paper Cleaning Paper Roll Kitchen Foil Roll Package of Latex gloves Slide Rail for Cable Alignment* Bottles with Cleaning Solvent* Cable Knife* Cable Stripper* Screw Tap** Electric Torch** Metal Angle** Precision Angle** Water pump pliers** Set of Mandrel and Chisel** Rolls of Crepe Paper** First Aid Box** * Extension Set ** not included but recommended

Photo of toolbox available from Tyco

Semicon Stripping and insulation cutting tool

Cable Straightening Set

45

46

Substation

Substation Surge Arrester High Voltage Connection System (HVCS) 48 72

47

48

Surge Arrester

Surge Arrester Introduction Application Benets Design Concept I. Single Modules for single column and series parallel surge arresters A. Construction B. Housing material C. Applications II. The Single Column Design 52 52 52 52 53 53 53 53 54 54 54 51 51 51

III. The Module Series Parallel Design A. Voltage distribution and stress grading B. Thermal ageing and partial discharge C. Comparison between Series Parallel and standard single column design D. Electrical tests for Series Parallel surge arrester E. Advantages of the Series Parallel design Appropriate Surge Arrester Selection I. II. Electrical performance and housings Surge Arresters for System Voltages 123 kV and 170 kV

55 56 58 60 62

III. Surge Arresters for System Voltages 245 kV and 362 kV IV. Surge Arresters for System Voltages 420 kV and 550 kV V. Accessories

VI. Transmission Line Surge Arresters for Overhead Poles and Overhead Lines up to 150 kV 68 Additional Equipment Surge Counter Installations 70 71
49

4P11SR396 Series Parallel Surge Arrester

50

Introduction

Benets

Tyco Electronics Bowthorpe has been manufacturing surge arresters for over 60 years. Our knowledge and experience we use to develop our surge arrester range today. Tyco Electronics is well known for their insulation and protection products worldwide. The range of HV surge arresters up to 550 kV and line discharge classes from 2 up to 5 operates in 130 countries in diverse climates from the artic circle to the tropics. Since 1988 Tyco Electronics have designed the patented series parallel metal oxide surge arrester which is special in construction and provides many advantages over conventional single column and multiple columns porcelain and polymeric housed arresters. They were designed and tested to meet dened abnormal service conditions as detailed in Annex A of IEC 60099-4 (1991). The special construction of this series parallel surge arrester provides electrical and mechanical properties that cannot be obtained with single or multiple column types. In particular the geometry and unitary construction provides inherent voltage grading that does not require additional grading rings or further correction of the maximum continous operating voltage (Uc) required for arresters of conventional construction. For voltages up to 220 kV Tyco Electronics offers two types of Polymeric Single Column Surge Arrester which also have their benets based on the construction and design.

Low residual voltages High protection margins High TOV performance Inbuilt stress grading along the full length More effective grading per unit length than a single column type Similar stress distribution like single column type, but without stress grading ring Resistant against Radial stress based on the gap free Bowthorpe patented construction Safe non-shattering short circuit behavior to higher current levels High-energy handling Direct molded housing to prevent moisture ingress Hydrophobic and tracking and erosion resistant silicone housing High pollution performance Excellent cantilever and tensile performance Excellent mechanical, vibration and impact withstand capability Extremely strong mechanical strength Low thermal ageing of varistor insulation Smaller footprint than equivalent single column SA with grading ring Modular design for quick installation and commission Light weight Capable to withstand seismic condition Uniform current sharing Maintenance free Tested in accordance with IEC60099-4 at independent accredited laboratories Quality design and manufacturing, ISO 9001 and 14001 compliant

Application
This range of Silicone Rubber housed surge arresters is applicable for substation equipment and transmission lines. Because of their high cantilever strength, they can be used to replace the cable support insulators on HV terminations. This results in simplied installation for HV terminations at reduced cost which is aesthetically more acceptabIe to the general pubIic.

51

Design Concept

Many 1-column porcelain housed and non-integrated polymeric housed type surge arresters have some limits. A few of them are the control of uniform stress grading and the radial eld strength which are the most important issues in these surge arrester design types. The high radial eld would lead to discharge in the surge arrester enclosure between the porcelain inside and the metal oxide varistors.

B. Housing material Housing material is a service proven formulation of Silicone Rubber. The silicone housing was developed using the knowledge accumulated over 35 years of internal Tyco Electronics materials science expertise and experience, resulting in an optimum shed prole and a material with excellent tracking and erosion resistance. This range of Silicone Rubber housed surge arresters has been fully tested to meet the very severe pressurerelief tests.

I. Single Modules for Single Column and Series Parallel Surge Arrester A. Construction The Tyco Electronics Bowthorpe patented surge arrester construction eliminates the air gap by direct moulding of the silicone rubber housing onto the wrapped ZnO varistor elements and the terminal assembly. The applied ZnO varistors ensure a very good electrical behaviour. The polymeric housing and the shed form (gure 1a) shows a good performance in salt-fog tests.

C. Application The advantages of the construction and the housing material are used for the Tyco Electronics Polymeric Surge Arrester independant if they are build in a single column design or in the series parallel design.

Excellent hydrophobicity

Stainless Steel Terminal Block Aluminium End Block Corona Ring

Safe non-shattering failure mode Intermediate metal work

Silicone Rubber Housing

Heat Sink ZnO Varistor Element

Die Cast Aluminium Sealing End Insulated base

Figure 1a: Tyco Electronics Bowthorpe surge arrester core and series parallel surge arrester.

Track and Erosion Resistant

52

II. The Single Column Design Tyco Electronics offers two types of single column Surge Arrester. The construction of the arrester type HSR is manufactured with the above described modules. These arresters are available for voltages up to 132 kV as a class 2 Surge Arrester. The type named PCA is designed as a class 3 Surge Arrester for voltages from 30 kV up to 220 kV.

Aluminium End Fitting

Cage Design

Moulded Silicone Sheds Figure 1b: Single column surge arrester and core in cage design (type PCA) ZnO Blocks

III. The Module Series Parallel Design Especially for higher voltages are some features like voltage distribution, stress grading, thermal ageing, partial discharge and the weight important for the design of the Surge Arrester. Tyco Electronics developed the Module Series Parallel Design to build up the advantages for these higher voltages. A. Voltage distribution and stress grading The voltage distribution is largely governed by the surge arrester geometry and intermediate plates. The intermediate connection plates of the series parallel surge arresters provide additional natural grading capacitance. The intermediate connection plates have stray capacitances which cascade and shunt to earth. Furthermore, the resistance and capacitance of the non-linear varistors also provide voltage grading. The equivalent cascade capacitance network (Fig. 1c) gives more uniform electric eld distribution when compared it with standard single column porcelain or non-porcelain house surge arrester with or without grading ring. Intermediate connecting plates assist the reduction in radial stress at extremely high voltage sections. The overall geometry of the modular surge arrester is such that both radial and longitudinal voltage stress was at an acceptable value at an extremely high system operating voltage.

Pedestal Base

Equivalent circuit network (Fig. 2a) can only handle the varistor element in its linear model either before or after the threshold turn on point. For the former, varistors have high resistance and its capacitance that dictates the surge arrester voltage grading. Beyond the turn on point the varistors have low resistance and this dominates the voltage grading. Further more for the former case, although the varistor or varistors are seeing high stress, the equivalent network as shown in gure 2a, has high source impedance (Z). Under these conditions the voltage across the varistor will collapse as soon as any signicant current commences to ow. The high equivalent source impedance effectively limited the voltage and current that can be applied to the varistor elements located in top surge arrestor section high stress region. It is in this context that further consideration must be given to actual ageing mechanism. Thermal ageing of the varistor would be caused by the lack of self limiting under the combination of high stress and low source impedance. The series parallel surge arrester design has eliminated both, thermal and partial discharge ageing to the metal oxide arrester. The Series Parallel surge arrester has no internal air gaps and therefore requires no grading ring to avoid internal ionisation. Figure 2b shows the coaxial circuit approximation model and gure 2c shows typical results obtained and conrmed the near uniform longitudinal voltage stress distribution. The Series Parallel surge arrester does not require external means such as grading rings, to aid the voltage distribution.

Key RMO,X Voltage-dependent resistance of section x CMO,X Capacictance of section x Ce, X Stray Capacitance to earth at node x n number of sections Figure 1c: Equivalent electric circuit network and the additional capacitance introduced by the series parallel surge

B. Thermal ageing and partial discharge An exponential longitudinal voltage grading of a surge arrester is undesirable phenomenon for varistor disks especially for those which are in top of the Surge Arrester. Low energy ionisation of the parallel air gap due to the high electrical stress would lead to ageing and failure of the varistor insulation. It has been established that partial discharge activity in close proximity to metal oxide varistors will lead to rapid ageing and premature failure. Therefore, the conventional single column arrester requires a grading ring for the additional reasons other than uneven eld or thermal considerations.

53

Current (2.0 kA/div) CH1 Current (2.0 kA/div) CH2 Current (2.0 kA/div) CH3 Trace Zeros 0 10 20 30 40 50 60 70 80 90 100 Time (s)

Figure 2a: Equivalent network

D. Series Parallel surge arrester electrical tests The following standard IEC routine testing for every series parallel surge arrester units: Reference voltage measurement Partial discharge measurement Leakage current measurement Residual voltage measurement In addition, a proprietary internal procedure was introduced to check the current sharing of parallel columns within a series parallel surge arrester. A proprietary process ensures that between parallel columns the lowest practical differences in characteristics can be employed in one complete series parallel surge arrester. Therefore, residual voltages, energy absorption and heat dissipation are shared among the parallel units.
Figure 2b: Field plot of series surge arrester using a coaxial circuit approximation model

E. Installation and maintenance advantages of the series parallel design Good stress grading without the need of oversize grading ring Light weight no heavy lifting equipment is required for installation Light weight no heavy duty foundation is required for the surge arrester Modular design quick installation and commission Lattice structure exceptional strong mechanical strength Non shatter of the surge arrester housing transportation easiness Non shatter of the surge arrester housing no damage to personal and nearby expensive equipments Good pollution performance maintenance free Environmental acceptable material maintenance free The series parallel design is capable to withstand seismic condition set in the current international standards which warrants reliable maintenance in all regions.

Figure 2c: Field plot result of series parallel surge arrester A Varistor non-conduct B Varistor partially conduct C Varistor fully conduct

C. Comparison between series parallel and single column design There are differences and similarities between the eld plot to a standard single column porcelain house surge arrester and the Series Parallel design. They are summarized as follows: The Series Parallel arrester has more effective grading per unit length than the single column type 54

Specially a Series Parallel 4P type exhibits similar stress distribution to the IEC example calculations, but without use the oversize diameter voltage grading rings Radial stress is an issue for many porcelain housed design due to the inbuilt air gap between the varistor and the housing inner wall but not for the gap free (integrated housing) Tyco Electronics patented construction

Surge Arrester Selection

Electrical Performance System Voltage Rated Voltage Line Discharge Class Long Duration Current (A) 3 2 3 4 5 2 3 3 4 5 2 3 3 4 5 3 4 5 3 4 5 5 5 5 640 450 750 1100 1500 450 640 750 1100 1500 450 750 640 920 1500 750 1100 1500 920 1100 1500 1500 1500 1800 Nominal Discharge Current (4/10 s) (kA) 10 10 10 20 20 10 10 10 20 20 10 10 10 20 20 10 20 20 20 20 20 20 20 20 Rated Short Circuit Current (kA) 65 40 40 63 63 40 65 40 63 63 40 40 65 63 63 40 63 63 63 63 63 63 63 63 Energy Capability at Ur acc. to IEC 60099-4 (kJ/kV) 7.8 4.5 7.0 10.8 12.5 4.5 7.8 7.0 10.8 12.5 4.5 7.0 7.8 10.8 12.5 7.0 10.8 12.5 9.4 10.8 12.5 16.4 12.5 16.4 Type Page

(kV) 123

(kV) 84120 84126 96126 96120 108120

PCA HSR 2PH 3P 4P HSR PCA 2PH 3P 4P HSR 2PH PCA 3P 4P 2PH 3P 4P 3P 3P 4P 5P 4P 5P

8 8 8 8 8 8 8 8 8 8 8 8 10 10 10 10 10 10 10 12 12 12 12 12

Neutral Ground 170

75 132150 132150 132150 132

Neutral Ground Neutral Ground 245

96 96 180198 180214 180214

Neutral Ground 362

168 240290 260290

Neutral Ground 420

180 336-360 330393 336360

550

396-444 420468

High current inpulse (4/10 s) 100 kA (for all Surge Arrester types)

PCA

HSR

2PH

3P

4P 55

Surge Arrester for System Voltages 123 kV and 170 kV

Protective Characteristics System Voltage Ur* Uc** Line Discharge Class Max. U res tested with current wave Switching surge Lightning Current 30/60 s 8/20 s 250 A 1000 A 5 kA 10 kA 20 kA (kV) 169 189 209 239 171 178 183 193 193 198 208 216 218 221 241 253 191 191 198 205 213 213 220 227 235 242 249 188 195 202 202 209 231 207 229 151 252 269 299 264 274 274 284 293 260 270 279 289 257 193 191 (kV) 180 201 222 254 183 192 197 208 208 213 224 232 235 237 259 272 203 203 210 218 226 226 234 242 249 257 265 198 206 213 213 221 244 218 241 162 267 286 318 280 291 291 301 312 274 285 295 305 271 208 203 (kV) 209 234 259 296 209 219 225 237 237 243 256 265 268 271 296 311 227 227 235 244 253 253 262 270 279 288 296 219 228 236 236 245 270 240 265 185 311 333 370 314 325 325 337 349 304 315 326 338 298 237 227 (kV) 219 245 270 209 225 235 242 255 255 261 275 285 288 291 318 334 241 241 250 260 269 269 278 287 297 306 315 232 241 250 250 259 285 253 280 199 325 348 386 334 346 346 358 371 321 333 345 357 314 255 241 (kV) 240 268 296 339 248 259 266 281 281 288 303 314 317 321 350 369 261 261 271 281 291 291 301 311 321 311 341 249 258 268 268 278 306 271 299 219 356 381 423 361 374 374 388 401 345 357 370 383 337 281 261 Steep Current 1/20 s 10 kA (kV) 238 266 294 336 256 267 273 288 288 295 309 320 323 327 355 373 272 272 281 291 301 301 311 321 331 340 351 262 272 281 281 291 319 283 311 223 354 378 420 374 388 388 401 414 362 375 388 400 353 288 272

(kV) 123

Neutral Ground 170

(kV) 84 96 108 120 84 87 91 95 96 98 102 106 108 110 120 126 95 96 98 103 106 108 110 114 120 121 126 96 98 103 105 108 120 108 120 75 132 138 150 132 138 140 144 150 132 138 144 150 132 96 96

(kV) 67.2 76.8 86.4 96.0 67.0 70.0 73.0 76.0 76.8 79.0 82.0 85.0 86.4 88.0 96.0 101.0 76.0 76.8 79.0 82.4 84.8 86.4 88.0 91.2 96.0 96.8 101.0 76.8 79.0 82.4 84.0 86.4 96.0 86.4 96.0 60.0 106.0 110.0 120.0 106.0 110.0 112.0 115.0 120.0 106.0 110.0 115.0 120.0 105.0 76.8 76.8

3 3 3 3 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 5 5 2 3 3 3 3 3 3 3 3 4 4 4 4 5 2 3

Neutral Ground Neutral Ground


* ** *** ****

Ur Rated Voltage Surge Arrester with other characterstics are available on request Uc Cont. Operating voltage TOV curves are given in Technical data for selected Surge Arrester (on request) Accessories selection see on the pages 6267

56

Temporary Overvoltage capability for 1 sec*** (kV) 96.6 110.0 124.0 138.0 97.7 102.0 106.0 111.0 112.0 115.0 120.0 124.0 127.0 128.0 140.0 147.0 109.0 110.0 113.0 118.0 121.0 124.0 126.0 131.0 138.0 139.0 145.0 115.0 117.0 122.0 124.0 128.0 141.0 119.0 132.0 87.5 152.0 159.0 173.0 151.0 159.0 160.0 166.0 172.0 159.0 162.0 170.0 176.0 145.0 112.0 110.0

Creepage length

Overall height

(mm) 3625 3625 3625 3625 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 3975 2650 3625 4725 4725 2650 5300 5300 5300 5300 5300 5300 5300 5300 5300 3975 3975

(mm) 1085 1085 1085 1085 1428 1428 1428 1428 1428 1428 1428 1428 1428 1428 1428 1428 1454 1454 1454 1454 1454 1454 1454 1454 1454 1454 1454 1500 1500 1500 1500 1500 1500 1838 1838 950 1085 1485 1485 952 1936 1936 1936 1936 2000 2000 2000 2000 1951 1428 1454

Rec. Min. distance between phase centers (mm) 880 993 1106 1218 841 1133 1168 1203 1212 1238 1274 1309 1325 1344 1438 1494 1337 1346 1373 1412 1440 1459 1478 1516 1572 1581 1628 1612 1639 1678 1697 1725 1838 1725 1838 759 1851 1908 2020 1685 1741 1760 1798 1854 1951 2007 2064 2120 1951 1212 1346

Rec. Min. distance between phase to earth (mm) 502 567 632 698 455 475 495 516 518 536 556 577 586 597 651 684 516 521 536 559 575 586 597 619 652 657 684 521 536 559 570 586 651 586 651 407 1023 1055 1121 716 749 760 782 814 717 749 782 814 716 521 521

Max. Cantilever load

Weight

Product code****

(N) 2500 2500 2500 2500 600 600 600 600 600 600 600 600 600 600 600 600 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 2000 2000 2000 2000 2000 2000 2875 2875 900 2500 900 500 500 500 500 1875 1875 1875 1875 2750 600 1000

(kg) 26.5 26.5 26.5 36.5 17 17 17 17 17 17 17 17 17 17 17 17 35 35 35 35 35 35 35 35 35 35 35 65 65 65 65 65 65 64 64 11

PCA3-84 PCA3-96 PCA3-108 PCA3-120 3HSRC(P)84L1E1M0(5) 3HSRC(P)87L1E1M0(5) 3HSRC(P)91L1E1M0(5) 3HSRC(P)95L1E1M0(5) 3HSRC(P)96L1E1M0(5) 3HSRC(P)98L1E1M0(5) 3HSRC(P)102L1E1M0(5) 3HSRC(P)106L1E1M0(5) 3HSRC(P)108L1E1M0(5) 3HSRC(P)110L1E1M0(5) 3HSRC(P)120L1E1M0(5) 3HSRC(P)126L1E1M0(5) 2P3HSRC95L2E2M4 2P3HSRC96L2E2M4 2P3HSRC98L2E2M4 2P3HSRC103L2E2M4 2P3HSRC106L2E2M4 2P3HSRC108L2E2M4 2P3HSRC110L2E2M4 2P3HSRC114L2E2M4 2P3HSRC120L2E2M4 2P3HSRC121L2E2M4 2P3HSRC126L2E2M4 3P3SR96L2E2M7-4 3P3SR98L2E2M7-4 3P3SR103L2E2M7-4 3P3SR105L2E2M7-4 3P3SR108L2E2M7-4 3P3SR120L2E2M7-4 4P3SR108L2E2M7 4P3SR120L2E2M7 2HSRC(P)75L1E1M0(5) PCA3-132 PCA31-138 PCA31-150 2P4HSRC132L2E2M4 2P4HSRC138L2E2M4 2P4HSRC140L2E2M4 2P4HSRC144L2E2M4 2P4HSRC150L2E2M4 3P4SR132L2E2M7 3P4SR138L2E2M7 3P4SR144L2E2M7 3P4SR150L2E2M7 4P4SR132L2E2L7 3HSRC(P)96L1E1M0(5) 2P3HSRC96L2E2M4

46 46 46 46 46 84 84 84 84 86 17 35

57

Surge Arrester for System Voltages 245 kV and 362 kV

Protective Characteristics System Voltage Ur* Uc** Line Discharge Class Max. U res tested with current wave Switching surge 30/60 s 250 A (kV) 3 3 3 3 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 3 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 3 350 379 389 389 349 361 361 373 385 385 397 397 421 345 357 357 369 381 393 393 393 332 472 522 522 522 539 539 556 556 556 573 495 514 514 533 533 533 552 552 552 349 1000 A (kV) 372 402 413 413 368 381 381 394 407 407 419 419 445 364 377 377 389 402 414 414 414 353 498 551 551 551 569 569 587 587 587 605 522 542 542 562 562 562 583 583 583 368 Lightning Current 8/20 s 5 kA (kV) 433 468 480 480 408 422 422 436 450 450 464 464 492 401 414 414 428 442 456 456 456 395 552 611 611 611 630 630 650 650 650 670 575 597 597 619 619 619 641 641 641 408 10 kA (kV) 453 489 502 502 431 446 442 461 475 471 490 486 520 422 437 437 451 466 480 480 480 420 582 645 645 645 666 666 686 686 680 707 606 629 629 652 652 652 675 675 675 431 20 kA (kV) 496 536 550 550 463 479 479 495 511 511 527 527 558 452 468 468 483 499 514 514 514 454 625 692 692 692 715 715 737 737 737 760 648 673 673 698 698 698 723 723 723 463 Steep Current 1/20 s 10 kA (kV) 492 532 546 546 484 500 500 516 532 532 548 548 580 472 487 487 503 517 533 533 564 466 656 723 723 723 745 745 767 767 767 789 682 705 705 731 731 731 756 756 756 484

(kV) 245

(kV) 180 192 196 198 180 183 186 192 194 198 201 205 214 180 183 186 192 198 201 204 214

(kV) 144 154 157 158 144 146 149 154 155 158 161 164 171 144 146 149 154 158 161 153 171 134 192 211 214 217 221 223 226 229 230 232 208 211 214 217 221 223 226 230 232 144

Neutral Ground 362

168 240 264 268 271 276 279 283 286 288 290 260 264 268 271 276 279 283 288 290

Neutral Ground

180

* ** *** ****

Ur Rated Voltage Surge Arrester with other characterstics are available on request Uc Cont. Operating voltage TOV curves are given in Technical data for selected Surge Arrester (on request) Accessories selection see on the pages 6267

58

Temporary Overvoltage capability for 1 sec*** (kV) 207 221 225 228 210 216 219 225 229 232 237 242 250 198 201 204 211 218 221 224 235 193 283 312 316 320 326 329 334 337 339 342 286 290 295 298 303 307 311 317 319 210

Creepage length

Overall height

(mm) 5440 7250 7250 7250 6625 6625 6625 6625 6625 6625 6625 6625 6625 6625 6625 6625 6625 6625 6625 6625 6625 5300 9275 9275 9275 9275 9275 9275 9275 9275 9275 9275 10600 10600 10600 10600 10600 10600 10600 10600 10600 6625

(mm) 1675 2170 2170 2170 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 1936 3500 3500 3500 3500 3500 3500 3500 3500 3500 3500 4000 4000 4000 4000 4000 4000 4000 4000 4000 3500

Rec. Min. distance between phase centers (mm) 2305 2415 2453 2472 2402 2430 2458 2515 2534 2571 2599 2637 2722 2402 2430 2458 2515 2571 2599 2628 2722 2023 2966 3192 3229 3257 3304 3333 3370 3398 3417 3436 3154 3192 3229 3257 3304 3333 3370 3417 3436 2402

Rec. Min. distance between phase to earth (mm) 1284 1349 1370 1381 978 993 1009 1042 1053 1075 1091 1113 1161 977 993 1009 1042 1075 1091 1107 1161 912 1303 1433 1454 1471 1498 1514 1536 1552 1563 1574 1411 1433 1454 1471 1498 1514 1536 1563 1574 977

Max. Cantilever load

Weight

Product code****

(N) 1750 1750 1750 1750 1750 1750 1750 1750 1750 2625 2625 2625 2625 2625 2625 2625 2625 500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 2250 2250 2250 2250 2250 2250 2250 2250 2250 1750

(kg) 40.5 53 53 53 103 103 103 103 103 103 103 103 103 108 108 108 108 108 108 108 108 46 141 141 141 141 141 141 141 141 141 141 170 170 170 170 170 170 170 170 170 103 PCA32-180 PCA33-192 PCA33-196 PCA33-198 3P5SR180L2E2M7-4 3P5SR183L2E2M7-4 3P5SR186L2E2M7-4 3P5SR192L2E2M7-4 3P5SR194L2E2M7-4 3P5SR198L2E2M7-4 3P5SR201L2E2M7-4 3P5SR205L2E2M7-4 3P5SR214L2E2M7-4 4P5SR180L2E2M4-5 4P5SR183L2E2M4-5 4P5SR186L2E2M4-5 4P5SR192L2E2M4-5 4P5SR198L2E2M4-5 4P5SR201L2E2M4-5 4P5SR204L2E2M4-5 4P5SR214L2E2M4-5 2P4HSRC168L2E2M4 3P7SR240L2E2M7-4 3P7SR264L2E2M7-4 3P7SR268L2E2M7-4 3P7SR271L2E2M7-4 3P7SR276L2E2M7-4 3P7SR279L2E2M7-4 3P7SR283L2E2M7-4 3P7SR286L2E2M7-4 3P7SR288L2E2M7-4 3P7SR290L2E2M7-4 4P8SR260L2E2M7 4P8SR264L2E2M7 4P8SR268L2E2M7 4P8SR271L2E2M7 4P8SR276L2E2M7 4P8SR279L2E2M7 4P8SR283L2E2M7 4P8SR288L2E2M7 4P8SR290L2E2M7 3P5SR180L2E2M7

59

Surge Arrester for System Voltages 420 kV and 550 kV

Protective Characteristics System Voltage Ur* Uc** Line Discharge Class Max. U res tested with current wave Switching surge 30/60 s 250 A (kV) 420 (kV) 336 336 360 360 330 360 336 360 381 385 389 393 336 360 550 396 400 404 408 411 396 400 404 408 411 415 419 420 423 444 405 409 413 416 420 424 428 431 435 444 420 444 420 444 468
* ** *** ****

Lightning Current 8/20 s 5 kA (kV) 765 760 810 816 729 796 746 801 939 939 939 994 746 769 994 994 994 994 994 1003 1003 1003 1003 1003 1003 1033 1033 1033 1094 1028 1028 1028 1028 1028 1028 1094 1094 1094 1094 1033 1094 1028 1094 1127 10 kA (kV) 808 802 856 862 769 839 786 844 990 990 990 1048 786 839 1048 1048 1048 1048 1048 1057 1057 1057 1057 1057 1057 1089 1089 1089 1153 1083 1083 1083 1083 1083 1083 1153 1153 1153 1153 1089 1153 1083 1153 1188 20 kA (kV) 868 862 919 925 823 898 842 904 1060 1060 1060 1122 842 898 1122 1122 1122 1122 1122 1132 1132 1132 1132 1132 1132 1166 1166 1166 1235 1160 1160 1160 1160 1160 1160 1235 1235 1235 1235 1166 1235 1160 1235 1272

Steep Current 1/20 s 10 kA (kV) 902 901 958 969 855 934 883 945 1098 1098 1098 1161 915 934 1161 1161 1161 1161 1161 1175 1175 1175 1175 1175 1175 1208 1208 1208 1341 1208 1208 1208 1208 1208 1208 1282 1282 1282 1282 1208 1277 1208 1282 1319

1000 A (kV) 691 686 732 737 663 723 678 728 854 854 854 904 678 723 904 904 904 904 904 912 912 912 912 912 912 939 939 939 994 934 934 934 934 934 934 994 994 994 994 939 994 934 994 1025

(kV) 269 269 288 288 264 288 269 288 305 308 311 314 269 288 317 320 323 326 329 317 320 323 326 329 332 335 336 338 355 324 327 330 333 336 339 342 345 348 355 336 355 336 355 374 4 4 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

(kV) 655 650 693 698 629 686 643 691 810 810 810 857 643 686 857 857 857 857 857 864 864 864 864 864 864 891 891 891 943 886 886 886 886 886 886 943 943 943 943 891 934 886 943 972

Ur Rated Voltage Surge Arrester with other characterstics are available on request Uc Cont. Operating voltage TOV curves are given in Technical data for selected Surge Arrester (on request) Accessories selection see on the pages 6267

60

Temporary Overvoltage capability for 1 sec*** (kV) 388 397 423 426 364 397 370 397 419 424 428 432 370 396 436 440 444 449 452 436 440 444 449 452 457 461 463 465 488 446 450 454 458 463 466 471 474 479 486 462 488 462 488 512

Creepage length

Overall height

(mm) 10600 11925 11925 13250 10600 11925 13250 13250 13250 13250 13250 13250 11925 11925 13250 13250 13250 13250 13250 14575 14575 14575 14575 14575 14575 14575 14575 14575 14575 14575 15900 15900 15900 15900 15900 15900 15900 15900 15900 14575 14575 15900 15900 15900

(mm) 4000 4500 4500 5000 3812 4575 5075 5075 5075 5075 5075 5075 4575 4575 5075 5075 5075 5075 5075 5575 5575 5575 5575 5575 5575 5575 5575 5575 5575 5575 6075 6075 6075 6075 6075 6075 6075 6075 6075 5575 5575 6075 6075 6075

Rec. Min. distance between phase centers (mm) 3868 3868 4094 4094 3812 4094 3868 4094 4291 4329 4367 4404 3868 4094 4432 4470 4508 4545 4573 4432 4470 4508 4545 4573 4611 4649 4658 4686 4884 4517 4555 4592 4620 4658 4696 4733 4761 4799 4884 4658 4884 4658 4884 5109

Rec. Min. distance between phase to earth (mm) 1824 1824 1954 1954 1791 1954 1824 1954 2068 2089 2111 2133 1824 1954 2149 2171 2193 2214 2231 2149 2171 2193 2214 2231 2252 2274 2279 2296 2410 2198 2220 2241 2258 2279 2301 2323 2339 2361 2410 2279 2410 2279 2410 2540

Max. Cantilever load

Weight

Product code****

(N) 1375 1250 1250 1125 2250 2125 2000 2000 2000 2000 2000 2000 2400 2400 2000 2000 2000 2000 2000 1875 1875 1875 1875 1875 1875 1875 1875 1875 1875 1875 1750 1750 1750 1750 1750 1750 1750 1750 1750 2200 2200 2000 2000 2000

(kg) 159 178 178 197 170 190 210 210 210 210 210 210 236 236 210 210 210 210 210 230 230 230 230 230 230 230 230 230 230 250 250 250 250 250 250 250 250 250 250 250 250 250 250 250 3P8SR336L2E2M7-4 3P9SR336L2E2M7-4 3P9SR360L2E2M7-4 3P10SR360L2E2M7-4 4P8SR330L2E2M7 4P9SR360L2E2M7 4P10SR336L2E2M7 4P10SR360L2E2M7 4P10SR381L2E2M7 4P10SR385L2E2M7 4P10SR389L2E2M7 4P10SR393L2E2M7 5P9SR336L2E2M7 5P9SR360L2E2M7 4P10SR396L2E2M7 4P10SR400L2E2M7 4P10SR404L2E2M7 4P10SR408L2E2M7 4P10SR411L2E2M7 4P11SR396L2E2M7 4P11SR400L2E2M7 4P11SR404L2E2M7 4P11SR408L2E2M7 4P11SR411L2E2M7 4P11SR415L2E2M7 4P11SR419L2E2M7 4P11SR420L2E2M7 4P11SR423L2E2M7 4P11SR444L2E2M7 4P12SR405L2E2M7 4P12SR409L2E2M7 4P12SR413L2E2M7 4P12SR416L2E2M7 4P12SR420L2E2M7 4P12SR424L2E2M7 4P12SR428L2E2M7 4P12SR431L2E2M7 4P12SR435L2E2M7 4P12SR444L2E2M7 5P11SR420L2E2M7 5P11SR444L2E2M7 5P12SR420L2E2M7 5P12SR444L2E2M7 5P12SR468L2E2M7

61

Modular Single Column Polymeric Surge Arrester Type HSR


Line lead accessories

L1
50 mm stud with washers and nut M 16

L2
Line clamp to suit conductors up to 16 mm

L5
Line clamp to suit conductors up to 35 mm

L6
Aluminium stem 30 mm x 80 mm high

Arrester Type = Rated Voltage Ur in kV 2HSRC


48.00 72.00 83.75 91.25 60.00 75.00 87.50 95.00

2HSRCP
96.00 98.75 102.50 106.25 108.00 110.00

HSRC HSRCP

Earthing accessories

E1
2 x M 10 x 20 mm Hexagonal headed set screws and spring washers

E2
Earth clamp to suit conductors up to 16 mm

E5
Earth clamp to suit conductors up to 35 mm

Mounting accessories

M5
4 Hole Pedestal Base 127-140 PCD (Pitch Circle Diameter)

M3
Set of 4 Polybre Base Insulators supplied with M5

M0
Without xing accessories

M10
Single Polybre Insulator

Sample: 3 HSRC 110 L2 E2 M4 Parallel Paths Arrester Housing Voltage Mounting Earth Terminal Line Terminal

62

Modular Polymeric Surge Arresters Type 2PH

L5
Line clamp to suit cables up to 35 mm

L3
Line clamp to suit cables up to 16 mm

Silicone Rubber Housed Arrester Module

L2
Aluminium stem 30 mm x 80 mm high

Aluminium Connection Strap

E5
Earth clamp to suit cables up to 35 mm

E2
Earth clamp to suit cables up to 16 mm

M4 Set of 2 Polybre Base Insulators

E1
2 x M10 x 20 mm Hexagonal headed set screws and spring washer

Sample: 2P 3HSRC 110 L2 E2 M4 Parallel Paths Series Stages Voltage Mounting Earth Terminal Line Terminal

63

Modular Polymeric Surge Arresters Type 3P

Corona Ring

L5
Line clamp to suit cables up to 35 mm

Silicone Rubber Housed Arrester Module

L3
Line clamp to suit cables up to 16 mm Silicone Aluminium intersection cross-arm

L2
Aluminium stem 30 mm x 80 mm high

Corona Shield

E5
Earth clamp to suit cables up to 35 mm

E2
Earth clamp to suit cables up to 16 mm

M7 3 Polybre Base Insulators connected to galvanised steel plate

E1
2 x M10 x 20 mm Hexagon headed set screws and spring washers

Sample: 3P 8SR 336 L2 E2 M7 Parallel Paths Series Stages Voltage Mounting Earth Terminal Line Terminal

64

Modular Polymeric Surge Arresters Type 4P

Corona Ring

L5
Line clamp to suit cables up to 35 mm

Silicone Rubber Housed Arrester Module

L3
Line clamp to suit cables up to 16 mm

Silicone Aluminium intersection cross-arm

L2
Aluminium stem 30 mm x 80 mm high

Corona Shield

E5
Earth clamp to suit cables up to 35 mm

E2
Earth clamp to suit cables up to 16 mm M7 4 Polybre Base Insulators connected to galvanised steel plate

E1
2 x M10 x 20 mm Hexagon headed set screws and spring washers

Sample: 4P 8SR 336 L2 E2 M7 Parallel Paths Series Stages Voltage Mounting Earth Terminal Line Terminal

65

Line Accessories

L5

L3

2P L2

HSR L6

Earthing accessories

E5

3P E5

2P E5

2P E2

3P E2 / HSRP E2

66

Mounting accessories

HSR M10

HSR M3

M5

M0 No mounting

4P M7

3P M7

67

Transmission Line Surge Arresters TLA

Lightning is responsible for approximately 65% of all of the non-scheduled outages occurring on transmission lines. Power supply utilities have veried the load losses due to voltage sags in their systems from transitory outages caused by lightning activity and in some regions they have found serious permanent damages on important lines. The effect of transitory disturbances on transmission lines can also be more critical in areas with high ground resistivity when associated with high lightning activity. Although a fault time is shorter than 1 minute, in many cases this is still unacceptable. This loss of supply is critical for all modern industries, electronical equipment and especially production processes. In most cases line arresters (TLA), electrically connected in parallel with the insulating string, have been considered as the most effective method currently applied to improve transmission line performance, especially when associated with improvements of the grounding system and usually presents the best benet versus cost relationship in reducing ashovers of the insulator string due to excessive voltages. Generic Technical data Specication IEC60099-4 Classication 10 kA Voltage Rating 10 to 192 kV High Current Performance 100 kA Line Discharge Class 2 Minimum Energy Capability acc. to IEC 60099-4 at Ur 4,5 kJ/kV Disconnect Device tested in accordance with IEC 60099-4 Insulation Material Silicone Rubber Vibration Tested Report No. BOE002000 Features & Benets HV arrester suspended from a transmission line giving enhanced transmission line performance Increasing system line voltage on standard insulated transmission lines Minimising circuit breaker operation with possible system outage resulting from back ashover on the transmission line Switching overvoltages are absorbed over the length of the line reducing the severity of surge at the substation Transmission systems can be operated even where sub-soil gives poor tower footing resistance Eliminating interrupted power supply for sensitive industrial processes Installing TLA on a standard 3 phase voltage system along the line, at calculated intervals, allows for optimum performance of the TLA, to give an increased system line voltage. Therefore eliminating the need to increase the standard insulation level required on conventional system upgrade.
Disconnect Device Earth Cable with Strain Relief Suspension Clamp

Earthing Conguration
TLA Disconnect E1
TLA Surge Arrester

Disconnect Device Grading Ring for voltages above 150 kV

Earth Connection

Silicone Rubber Insulation

TLA Strain Relief System E2


TLA Surge Arrester

Disconnect Device Earth Connection

TLA Surge Arrester

Accessories TLA Pivot Suspension Clamp


Suspension Clamp Assembly Copper Shoring Braid/Cable

Strain Relief Wire Connection

Galvanic Steel Clamp Straps & Podings Galvanised Steel Line palm M 16 x 35 Min. Full Thread

Aluminium Line Clamp

M 12 Connection For Shoring Braid/Cable

TLA Surge Arrestor

Clamp

Conductor Range Diameter A 180 217 267

Dimensions in mm B 80 90 100 120 C 90 110 120 140 D 40 50 64 86

U Bolt Torque 45 Nm 45 Nm 75 Nm 75 Nm

Weight

L2 L3 L4 L5

9.519 mm 1830 mm 3045 mm 4565 mm

1.8 kg 3.0 kg 4.3 kg 6.0 kg

320

68

TLA 1: 1545 kV

TLA 2: 4096 kV

TLA 3: 108144 kV

TLA 4: 150192 kV

Protective Characteristics
Ur* Uc** Max. U res tested with current wave Switching surge 30/60 s (kV) (kV) 125 A (kV) 500 A (kV) Lithtning Current 8/20 s 5 kA (kV) 10 kA (kV) 20 kA (kV) Seep Temporary Creepage Overall Current Overlength height 1/20 s voltage capability for 1 s*** 10 kA (kV) (mm) (mm) (kV) Product code****

15 18 21 24 27 30 36 39 42 45 48 60 72 75 84 96 108 120 138 144 150 168 180 192

12.0 14.0 17.0 19.0 22.0 24.0 29.0 31.0 34.0 36.0 38.4 48.0 57.6 60.0 67.2 76.8 86.4 96.0 110.0 115.0 120.0 134.0 144.0 154.0

31.1 39.2 43.8 50.1 54.8 60.9 71.8 76.4 82.7 88.8 93.9 115.0 137.0 144.0 159.0 182.0 202.0 225.0 261.0 271.0 285.0 314.0 338.0 376.0

33.3 41.7 46.5 53.2 58.2 64.8 76.3 81.2 87.8 94.4 100.0 122.0 146.0 153.0 169.0 193.0 215.0 239.0 277.0 288.0 303.0 333.0 359.0 399.0

41.4 50.5 56.4 64.5 70.6 78.5 92.4 98.4 106.0 114.0 121.0 148.0 176.0 186.0 204.0 234.0 260.0 286.0 336.0 349.0 367.0 404.0 435.0 484.0

45.9 54.4 61.4 69.5 76.3 84.6 100.0 106.0 115.0 123.0 130.0 160.0 190.0 200.0 220.0 252.0 281.0 312.0 362.0 377.0 396.0 435.0 470.0 521.0

51.6 61.8 69.0 78.9 86.4 96.0 113.0 120.0 130.0 140.0 148.0 182.0 216.0 227.0 250.0 286.0 319.0 354.0 411.0 427.0 449.0 494.0 533.0 594.0

46.7 59.5 67.1 75.6 83.3 92.0 108.0 115.0 125.0 134.0 142.0 174.0 207.0 218.0 240.0 275.0 305.0 339.0 394.0 410.0 430.0 474.0 511.0 591.0

17.1 20.5 24.0 27.4 30.8 34.2 41.1 44.5 47.9 51.3 54.8 68.4 82.0 85.5 95.8 109.0 123.0 137.0 157.0 164.0 171.0 192.0 205.0 219.0

930 930 930 930 930 1310 1310 1310 2000 2000 2620 2620 2620 2620 4000 4000 3930 3930 6000 6000 5240 8000 8000 8000

321 321 321 321 321 476 476 476 476 476 952 952 952 952 952 952 1428 1428 1428 1428 1904 1904 1904 1904

TLA1B15L1E1M2 TLA1B18L1E1M0 TLA1B21L1E1M0 TLA1B24L1E1M0 TLA1B27L1E1M0 TLA1C30L1E1M0 TLA1C36L1E1M0 TLA1C39L1E1M0 TLA1E42L1E1M0 TLA1E45L1E1M0 TLA2C48L1E1M0 TLA2C60L1E1M0 TLA2C72L1E1M0 TLA2C75L1E1M0 TLA2E84L1E1M0 TLA2E96L1E1M0 TLA3C108L1E1M0 TLA3C120L1E1M0 TLA3E138L1E1M0 TLA3E144L1E1M0 TLA4C150L1E1M0 TLA4E168L1E1M0 TLA4E180L1E1M0 TLA4E192L1E1M0

* ** *** ****

Ur Rated Voltage Surge Arrester with other characterstics are available on request Uc Cont. Operating voltage TOV curves are given in Technical data for selected Surge Arrester (on request) Accessories selection see on left page

69

Surge Counters Type SC 12 & SC 13

The Tyco Electronics Bowthorpe EMP range of Surge Arrester monitoring instruments are fully tested for use with any manufacturers surge arrester. The SC 12 is a Surge Counter only, whilst the SC 13 provides the additional measurement of total leakage current. The analogue instrument provides a means of monitoring the current through the arrester and the leakage current over the surface of the arrester housing. Signicant changes after installation may indicate a deterioration in the arrester or a build up of surface contamination. These instruments, which require no auxiliary supply, are designed for installation in the earth connections of a single surge arrester or alternatively the SC 12 may be used with the common earth of a three phase set.

Fully weatherproofed and sealed for life they are housed in a one piece gravity die cast aluminium case coated to enhance its already high degree of resistance to surface corrosion. The glass viewing window is sealed in place, using a silicon rubber adhesive, and a desiccator is enclosed to ensure any residual moisture trapped during sealing is absorbed for the service life of the counter. Mounting is effected by means of an integrally cast lug at the rear of the case providing a single clearance hole for the galvanized steel M 12 bolt supplied. The SC 12 and SC 13 are service proven and require no special maintenance or servicing apart from general cleaning of the glass viewing window and the moulded epoxy resin line bushing.

Line termination M12 nickel plated brass tted with 2-nickel plated brass locknuts Moulded resin insulator Hermetically sealed glass display panel

M12 x 35 galvanized steel with full nut and springwasher

Ground terminal M12 Nickel plated brass tted with 2-nickel plated brass locknuts

Meter: Minimum count current: Maximum High Current Withstand: Nominal Residual Voltage withstand at 100 kA with 4/10 s Wave: Meter scale: SC 13 leakage:

6 digit cyclometer at least 5 counts/second 200 A 8/20 microsecond wave 100 kA 4/10 microsecond wave

5 kV peak 030 mA Peak (bilinear scale) Ref SC 13 2 050 mA Peak (bilinear scale) Ref SC 13L 2

Both counters can be supplied with an auxiliary contact rated 1,0 A 250V for connection to remote signaling equipment. If required put sufx e.g. SC 12/AC.

70

Installations

66 kV Surge Arresters Statkraft, Norway

110 kV Surge Arresters Estonia

132 kV Surge Arresters Statkraft, Norway

300 kV Surge Arrester Statnet

400 kV Surge Arrester Damhead Creek, UK

500 kV Surge Arrester Indonesia

400 kV Surge Arrester Statnet

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72

HV Connection System

HV Connection System Introduction Connectors for Copper or Aluminium conductors & Copper or Aluminium terminals 220 kV Bronze, Aluminium & Bimetal Range Connectors for Aluminium conductors & Aluminium or Copper terminals 330 kV Sinemex Range Connectors for Aluminium conductors & Aluminium or Copper terminals 550 kV Anti-Corona Range Connectors for Aluminium conductors & Aluminium or Copper terminals 800 kV Extra High Voltage Connectors UNIVERSAL Connectors 74

75

76

77

78 79

73

Introduction

For more than 60 years, Tyco Electronics SIMEL has been continuously expanding and manufacturing connectors for Grid Stations in France and throughout the world. The various ranges of: Bronze, Aluminium & Bimetallic connectors up to 220 kV Connectors according to NEMA-CC1 Standard up to 330 kV Connectors for Aluminium cables or tubes up to 550 kV Connectors up to 800 kV UNIVERSAL connectors are shown in the following pages as a small overview. These pages are only a capability of available connectors.

Therefore we recommend the customer to contact us with his requirements and we should be in position to nd the right solution for his application. It is necessary to know the conditions of the substation project like: Operating Voltage Conductor type (Material, Diameter) Nominal Current Short-circuit current Applicable Standards Connection type (bolted, crimped, welded) Working conditions Tyco Electronics SIMEL has expertise level into the substation elds and can provide technical support to customers engineering teams in order to establish the best selection of products t for each application. To nd a product for your application, please contact your representative Sales Engineer.

The products are subject to strict controls during the manufacturing, according to our quality control manual, in order to meet the requirements of the ISO 9001: 2000 & ISO 14001: 2004. All our connectors comply with criteria of standards such as IEC, VDE, NEMA, ANSI, etc The tests requested by the main worldwide standards like Heating test Electrical Resistance test Mechanical Cantilever test Short-Circuit current test RIV/Corona test have already been performed on our connectors. SIMEL laboratory is COFRAC accredited as an independent lab following ISO CEI 1725 and can perform usual required type tests such as temperature rise, resistance & mechanical

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Connectors for Copper or Aluminium conductors & Copper or Aluminium terminals 220 kV Bronze, Aluminium & Bimetal Range
Bolted Applications: Bronze connectors for Copper conductors to Copper conductors or copper terminals Aluminium connectors for Aluminium conductors to Aluminium conductors or Aluminium terminals Bimetal connectors for Aluminium or Copper conductors to Aluminium or Copper conductors or terminals Principle is provided by assembling a bimetallic sheet in between Aluminium and bronze part. Standard capacities: Al or Cu tube diameter: 20 to 120 mm Cu cable cross section: 50 to 600 mm2 Al cable cross section: 75 to 1144 mm2 Al or Cu stud diameter: M12 to 60 mm Al or Cu palm: 50, 60, 80, 100, 125, 100x200 mm or whatever required Connectors are available such as: conductor ttings rigid, sliding & expansion busbar connectors & supports terminal connectors on stud or palms earthing & grounding applications possibility of providing 330 kV copper alloy range

Al. straight expansion terminal pad

Bi-metallic straight terminal pad

Bronze tee connector

Al. tee connector

Bi-metallic straight connector pad

Bronze straight expansion connector

75

Connectors for Aluminium conductors & Aluminium or Copper terminals 330 kV Sinemex Range
Applications: This range meets the requirements of NEMAC-CC1 1984 and 107 standards for a maximum operating voltage of 330 kV. It allows a bolted connection from: Aluminium conductors to Aluminium conductors or Aluminium terminals Aluminium conductors to copper terminals wherever applicable Al or Cu stud diameter: 20 to 80 mm Al or Cu palm: 50, 60, 80, 100, 125, 100x200 mm or whatever required Bundle spacing: 100, 200 mm, or whatever required Standard capacities: Al Tube diameter: 50 to 250 mm Al cable cross section: 75 to 1144 mm2 Connectors are available such as: conductor ttings terminal connectors on stud or palms earthing applications

Al. tee connector

Al. straight connector

76

Connectors for Aluminium conductors & Aluminium or Copper terminals 550 kV Anti-Corona Range
Applications: This range of connectors can be used up to 550 kV operating voltage It allows a bolted, welded or crimped connection from: Aluminium conductors to Aluminium conductors or Aluminium terminals Aluminium conductors to copper terminals wherever applicable Standard capacities: Al Tube diameter: 100 to 250 mm Al cable cross section: 75 to 2000 mm2 Al or Cu stud diameter: 20 to 60 mm Al or Cu palm: 50, 60, 80, 100, 125, 100x200 mm or whatever required Bundle spacing: 100, 200, 400 mm or whatever required Connectors are available such as: conductor ttings rigid, sliding & expansion busbar connectors & supports terminal connectors on stud or palms conductors spacers earthing applications

Al. spacer

Al. straight expansion connector

Al. straight connector

Al. Straight compression type terminal pad

77

Connectors for Aluminium conductors & Aluminium or Copper terminals 800 kV Extra High Voltage Connectors
800 kV Connectors for EHV Grids

Al. tee connector

Al. Straight terminal pad

78

Universal Connectors

Advantages: Adjustable on site Easy to install Controlled tightening (shear head bolt) High electrical contact efciency & stability

Al. UNIVERSAL terminal pad

79

80

Transmission

Transmission Tension Insulators Transmission Line Hardware Distribution Line Hardware 82 90 96

81

82

Tension Insulators

Tension Insulators Introduction Tension Insulators up to 52 kV Tension Insulators up to 72 kV 84 86 88

83

Introduction

Construction Tyco Electronics Tension Insulators were built as composite insulators. They are based on Raychems 30 years experience in the eld of crosslinked polymers for medium and high voltage applications. They consist of a polymeric housing of ethylene vinyl acetate (EVA) over pultruded berglass rod to which galvanized steel or aluminium end ttings are attached. By molding directly over the end tting, or by using a track resistant polyurethane, moisture ingress to the berglass rod is prevented. Composite Insulators are available for applications up to system voltages of 72 kV. They provide a reliable solution for power utilities and railway companies with installations in severely polluted environments all over the world. The core of a composite insulator is a pultruted ber glass rod which provides a high mechanical strength. In a direct injection molding process a non-tracking, erosion and UV resistant polymeric housing is molded directly onto the berglass rod. A corrosion resistant metal tting is crimped onto each end to the rod to provide a high mechanical strength. A new developed crimping control technology monitors the assembly process of the metal ttings and ensures that crimping forces cause no damage to the berglass rod while achieving a crimp that will withstand extremely high mechanical loads. Sealed with a tracking and erosion resistant polyurethane barrier, the core is protected from deterioration due to moisture ingress.

High strength pultruded ber glass rod

Field proven interfacial sealing

Non tracking, UV resistant EVA housing

Corrosion resistant crimped end ttings

84

Application Composite insulators are available as tension (suspension), line post and station post insulators. For railway applications, tension and strut composite insulators are available in a large variety of congurations. The maintenance free characteristics of Raychems EVA material have been demonstrated during service experience of more than 30 years. The Tension insulators are qualied to the requirements of the IEC 61109.

New products up to 230 kV A range of High Voltage silicone tension insulators from 69 kV to 230 kV will be available shortly. These insulators will cover normal, high and extra pollution levels. They will be available with a variety of end tting options, ball, socket, eye, clevis, tongue and Y-Clevis. They will also available with corona rings where required.

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Composite Tension Insulator up to 52 kV RST-DS46R-xx


General Technical Data Physical Properties Creepage Distance [mm] Dry Arc Distance [mm] Type of Sheds Core Diameter [mm] End Fittings Mechanical Connection Electrical Properties [kV] AC Wet Withstand Voltage AC Dry Withstand Voltage AC Wet Flashover Voltage AC Dry Flashover Voltage Impulse Withstand Voltage Impulse Flashover Voltage Housing Color Grey Color Red

1300 450 Alternating 21

Galvanised Steel

130 148 158 193 310 347

Available on request Available on request

Type Specic Technical Data


RST-DS46RBS SB CC CC CT CT TC TC TT TT

Physical Properties Number of Sheds Housing Material End Fittings Top Bottom Orientation Drawing Ball Socket N/A Available on request Socket Ball N/A Available on request Clevis Clevis parallel Available on request Clevis Clevis perpendicular Available on request Clevis Tongue parallel Available on request Clevis Tongue perpendicular Available on request Tongue Clevis parallel Available on request Tongue Clevis perpendicular Available on request Tongue Tongue parallel Available on request Tongue Tongue perpendicular Available on request 13 Available on request 18 Available on request 18 Available on request 13 Available on request 13 Available on request 13 Available on request 13 Available on request 13 Available on request 13 Available on request 13 Available on request

Mechanical Properties [kN] Specied Mechanical Load Routine Test Load 120 120 75 75 75 75 75 75 75 75

60

60

37.5

37.5

37.5

37.5

37.5

37.5

37.5

37.5

Drawing Dimensions [mm] A B C D E F 650 360 112.5 92 28 450 650 360 112.5 92 28 450 613 360 112.5 92 28 450 613 360 112.5 92 28 450 613 360 112.5 92 28 447 613 360 112.5 92 28 447 650 360 112.5 92 28 450 613 360 112.5 92 28 450 613 360 112.5 92 28 450 613 360 112.5 92 28 450

The Clevis and Tongue ttings can be supplied in any orientation. The Ball and Socket ttings are according to the IEC 120-16A. The product range is available in pollution class II and III according to IEC 815.

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Composite Tension Insulator up to 52 kV RST-DS46R-xx


Example: Top: Bottom: RST-DS46R-BS Ball Socket End Fittings: Ball

Socket

Clevis

Tongue

87

Composite Tension Insulator up to 72 kV RST-DS69R-xx


General Technical Data Physical Properties Creepage Distance [mm] Dry Arc Distance [mm] Type of Sheds Number of Sheds Core Diameter [mm] Housing Material End Fittings Mechanical Connection Drawing Mechanical Properties [kN] Specied Mechanical Load Routine Test Load Electrical Properties [kV] AC Wet Withstand Voltage AC Dry Withstand Voltage AC Wet Flashover Voltage AC Dry Flashover Voltage Impulse Withstand Voltage Impulse Flashover Voltage Housing Color Grey Color Red

1810 610 Alternating 18 21 Available on request

Galvanised Steel Available on request

75 37.5

180 180 191 350 434

Available on request Available on request

Type Specic Technical Data


RST-DS69REnd Fittings Top Bottom Orientation Ball Socket N/A Socket Ball N/A Clevis Clevis parallel Clevis Clevis perpendicular Clevis Tongue parallel Clevis Tongue perpendicular Tongue Clevis parallel Tongue Clevis perpendicular Tongue Tongue parallel Tongue Tongue perpendicular BS SB CC CC CT CT TC TC TT TT

Drawing Dimensions [mm] A B C D E F 796 510 112 92 28 596 796 510 112 92 28 596 759 510 112 92 28 596 759 510 112 92 28 596 759 510 112 92 28 596 759 510 112 92 28 596 759 510 112 92 28 596 759 510 112 92 28 596 759 510 112 92 28 596 759 510 112 92 28 596

The Clevis and Tongue ttings can be supplied in any orientation. The Ball and Socket ttings are according to the IEC 120-16A. The product range is available in pollution class II and III according to IEC 815.

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Composite Tension Insulator up to 72 kV RST-DS69R-xx


Example: Top: Bottom: RST-DS69R-BS Ball Socket End Fittings: Ball

Socket

Clevis

Tongue

89

90

Hardware for Transmission Lines

Hardware for Transmission Lines Introduction, Project Support Vibration Dampers Spacer Dampers and Spacers Pole Hardware Suspension Clamps Dead Ends Compression Fittings 92 93 93 94 95 95 95

91

Introduction

Project Support

Tyco Electronics developed Hardware for Overhead Transmission lines since over 20 years and has a lot of eld experience in these products. On the following pages we present an overview of our product ranges for Overhead Transmission Lines.

Spacer Dampers Vibration Dampers Spacers Pole Hardware Suspension Clamps Dead Ends Compression Fittings

With the products on the following pages we want to give you an overview of available product types. For these product ranges we concern to work close together with the customers on their projects to dene the right product from the wide product range. Therefore we do not present details of the products in this catalogue, which are available in different sizes and materials for a wide range of applications. If you are interested in products from the following pages, please contact your relevant sales representative. He will nd together with you the correct product for your special application.

92

Vibration Dampers
General Recommendations Vibration dampers are designed to eliminate conductor fatigue damage and line maintenance costs by effectively diminishing aeolian vibration, thereby allowing increased line tensions. All Tyco Electronics damping devices are designed for the single purpose of reducing vibration. This unitary function is entirely different from that of protecting against: (1) stress concentrations, (2) fretting of abrasion and (3) arc-over burning.

Stockbridge Vibration Dampers

Dogbone Vibration Dampers

Spiral Vibration Dampers

The Stockbridge vibration dampers are constructed with a 7 strand messenger cable to improve the damping. Damper weight and length will be optimized for maximum efciency.

The Dogbone vibration dampers are constructed with a 19 strand messenger cable to improve damping and fatigue performance. The design of the zinc weights eliminates water entrapment. The messenger cable has improved energy dissipation at low amplitude of exure.

Spiral Vibration Dampers are exceptionally effective against high frequency aeolian vibration of EHS or Alumoweld shield wires.

Spacer Dampers

2 Bundle Posilok Spacer Damper Spacer Dampers are recommended for multi-conductor bundles with industry standard spacing. The Spacer Damper is designed to withstand the forces and movements caused by transient conditions such as short circuit, differential icing, and wind loading without either causing damage themselves.

3 Bundle Posilok Spacer Damper The design accommodates both longitudinal movement of the subconductors, vertical sag differences, as well as compressive and tensile forces. The Spacer Damper can constitute a system which replaces conventional spacers and vibration dampers.

4 Bundle Bolted Spacer Damper Spacer Dampers will control both Aeolian vibration and subconductor oscillation to levels recognized as acceptable within the industry and to the customers expressed needs. Tyco Electronics will tailor the recommendations to terrain and design parameters.

Posilok Spacer
Posilok spacers are designed to maintain specied subconductor spacing. Furthermore, they are designed to withstand the forces and movements caused by transient conditions such as short circuit differential icing and wind loading without either causing damage to the subconductors or sustaining damage themselves. The Posilok spacer is exible enough to allow some longitudinal movement between subconductors and yet rigid enough to restrain the subconductors under adverse conditions. They provide a smooth, unitized construction which minimizes corona and presents a low level of RIV.

93

Pole Hardware

Yoke Plates and Clevis Eyes

Ball Clevis

Ball Eye Links

Bow Shackles (Anchor Shackles)

Ball Clevis Extension Links

Ball Eye Extension Links

Ball Hooks

Socket Clevis

Socket Tongues

D Shackle

Socket Clevis Extension Links

Clevis Tongues

Clevis Suspension Clamps

Trunnion Suspension Clamps

Suspension Clamp for Steel and Copper Conductors

Turnbuckles

Aluminium Angle Clamp

The devices above are available in different designs and sizes. Other devices of pole hardware are available on request. For more details please contact your relevant sales representative.

94

Suspension Clamps

Heliformed Suspension Unit Suspension clamps are designed to reduce the static stresses at the support point, as well as insure that the conductor is cushioned against the dynamic stresses of aeolian vibration. They also protect the conductor in the support area against impulse and power ashover.

Forged / Cast Bolted Suspension Clamp

Dead Ends
Wegde Tension Clamp Dead Ends are designed to x the transmission line at the pole. There are two possibilities to x the cable into the Clamp: the wedge and the bolted solution. Bolted Tension Clamp

Compression Fittings
Full Tension Fittings Full Tension Fittings are designed to hold a minimum of 95% of the specic conductor breaking load.

Non-Tension Fittings Non-Tension Fittings are designed to hold nominally 10% of the conductor breaking load.

Spacers Spacers are designed to maintain conductor separation.

95

96

Hardware for Distribution Lines

Hardware for Distribution Lines Ties Splices Armor Rods Line Guards Heliformed Suspension Unit Fiber Optic Dead Ends Optical Tension Device Fiber Optic Suspension Unit 98 98 98 98 98 99 99 99

97

Ties
To insure proper t and service life, it is recommended that only insulators corresponding to C Neck, F Neck, or J Neck be used. The neck diameters and groove height dimensions appear in ANSI Standard for low and medium voltage pin type insulators and also at the beginning of each listing. Ties are recommended as an improvement over Armor Rods secured with hand tie wire. Ties are available as: Longspan Ties Distribution Ties Double Support Ties Side Ties Double Support Ties Spool Ties Quick Spool Ties

Splices
Splices are designed for joining ACSR or repairing ACSR when damage to the core is suspected. Full Tension Splice will hold the full rated breaking strength and restore conductivity. Conductor Splices are designed as a single component outer layer assembly for sub-EHV conductor. All conductors, new or weathered, must be thoroughly scratch brushed until bright and clean and an inhibitor applied immediately prior to installation of the splice.

Armor Rods
Armor Rods are intended to protect the conductor on which they are being applied against bending and compression stresses, abrasion, and arc-over. The degree of protection needed on a specic line depends upon a number of factors such as line design, temperature, tension, exposure to wind ow, and vibration history on similar construction in the same area. Armor Rods should be considered as minimum protection for clamp style supports of bolted suspension arrangements. Armor Rods do not act as vibration dampers. They are designed to provide an extra degree of protection to the conductor at support points.

Line Guards
Line Guards are intended to protect the conductor against abrasion and arc-over and to provide repair. The degree of protection needed on a specic line depends upon a number of factors such as line design, temperature, tension, exposure to wind ow, and vibration history on similar construction in the same area. Line Guards are recommended as minimum for use with hand-tied spans of less than 300 feet in urban construction having no experience of vibration. Line Guards alone are not recommended for use in areas of suspected vibration. They are designed to provide an extra degree of protection to the conductor at support points.

Heliformed Suspension Unit


Heliformed suspension is intended for use on aluminium based conductors, alumoweld and galvanized steel strands. They are designed to reduce the static stresses at the support point, as well as insure that the conductor is cushioned against the dynamic stresses of aeolian vibration. They also protect the conductor in the support area against impulse and power ashover. Although Heliformed suspension provides improved protection over armor clamp or bare clamp attachments, in the case of known vibration, vibration dampers will be necessary. Consult Tyco Electronics for recommendations concerning Dogbone vibration dampers.

98

Fiber Optic Dead End


For ADSS cable Fiber Optic dead ends may be installed once as a temporary (less than 30 days) pulling device prior to its nal installation; as long as it is not stressed over 50% of its rated strength. The dead ends are sold as an assembly including reinforced rods, a dead end, clevis thimble, extension link and oval eye nut.

Fiber Optic Dead End


For OPGW cable The ber optic dead end may be installed once as a temporary (less than 30 days) pulling device prior to its nal installation; as long as it is not stressed over 50% of its rated strength. A ground clamp may be ordered with the dead end. Clamping over the OPDE or the OPRR assemblies is not permitted. Maximum Rated Holding Strength is 95% of the OPGW RTS.

Optical Tension Device (OTD)


For OPGW Fiber Cable Tyco Electronics new Optical Tensioning Device is designed for pulling OPGW ber cable to nal sag tension. Once the nal sag has been achieved, a permanent type dead end device should be installed promptly, followed by the removal of the tensioning device. This device should not be subjected to sag tension for an extended time period and it should never be utilized as permanent dead end device.

Fiber Optic Suspension Units


The ber optic xed suspension unit is a low cost assembly for installing ADSS cable. The aluminium housing is joined with stainless steel roll pins, which ensure positive alignment. The housing is cushioned on the inside with an EPDM liner which is specially sized to provide excellent slip strength ability and yet not impart any undue clamping stresses on the cable. A grounding lug, consisting of a 10 mm aluminium bolt tapped in the housing, is available as an option.

99

Notes

100

Energy Division The Energy Division, a global operating untit of Tyco Electronics develops manufactures and markets products and systems for the electrical power industry. Today, the Energy Division employs approximately 4000 people and annual sales amount to almost $ 800 million. Our products are extensively employed by power utilites and equipment manufacturers, in rail transport systems and in industry around the world.

All of the above information, including drawings, illustrations and graphic designs, reects our present understanding and is to the best of our knowledge and belief correct and reliable. Users, however, should independently evaluate the suitability of each product for the desired application. Under no circumstances does this constitute an assurance of any particular quality or performance. Such an assurance is only provided in the context of our product specications or explicit contractual arrangements. Our liability of these products is set forth in our standard terms and conditions of sale. Raychem, Bowthorpe, Dulmison, Simel, TE logo and Tyco Electronics are trademarks.

Tyco Electronics Raychem GmbH, Energy Division Finsinger Feld 1 85521 Ottobrunn/Munich, Germany Phone: +49-89-6089-0 Fax: +49-89-6096345 http://energy.tycoelectronics.com

Tyco Electronics EPP 1384 12/07

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