HVCS Products

Technical Training
October 2012

HVCS = High Voltage Connection System

HVCS Global
Markets

AIS Substations HVDC Transmission Lines

page 2
 HVCS Global
Energy Flow – Different Steps

Generators Elevation S/S Transmission lines Distribution S/S Distribution lines

G
(kV)

400
220

63
30
0

page 3
HVCS Global
Substation purpose

- CONVERT (Transformer)

- PROTECT (Circuit Breaker)

- SWITCH (Disconnector)

- PROTECT (Lightning Arrester)

- MEASURE (CVT)

- COMMUNICATE (Wave Trap)

page 4
 1946 Creation of SIMEL

Classic
1969
Products

Anti-Corona
HVCS Global

1982

Sinemex

1985

800 kV

1992
Universal

1998
Hardware
& fittings
2005
400 kV
India
2008
HT° Fittings
2009
1200 kV
2010
Universal II
page 5

2011
AIS Substations applications
60-550kV s/s

66 - 220kV

“CLASSIC” Range

110 - 330kV

“SINEMEX” Range

400 - 550kV

“Anti-Corona” Range

page 6
AIS Substations applications
600-1200kV s/s & Accessories

600 - 1200kV

“UHV connectors” Range

Accessories

“Station fittings & cable supports”

Grounding

“Earthing & Grounding” connections

page 7
HVDC applications
Capabilities

Universal connectors

Shields & Adaptors & Supports

Pipes & Conductors Hardware

page 8
Transmission Lines applications
Hardware & Fittings (RTE spec. compliant)

Hardware

Compression fittings
Suspension clamp
(Slipping control)

page 9
Transmission Lines applications
High Temperature fittings (ACSS)

HT° Spacer
HT° Compression fittings damper

Heliform fittings HT° Warning

HT° Suspension clamp sphere
(Slipping control)

page 10
 Innovation in Transmission Line applications
AVISPHERE
PROTECTING THE BIODIVERSITY All metal: Works on phase
ROHS & REACH COMPLIANT conductor up to 500kV.
Light Weight: 600Grs no
additional boundary conditions
Universal: range taking from 12 to
to the line.
45mm O/D conductors.
Spherical: Fit for Ice loading
Classic & HT°°: Fit for any working
condition (limited ice retention)
condition including High temperature
conductors (up to 250°C)

Tool-less: No tool
required to install
Easy: Quick to
install (30 sec).
Alive: Fit for alive
installation by one
operator
Bi-Colour: Developed with
Ornithologists. Very attractive to
birds
250mm Dia: 5 times more
visible than spiral type.
Photo luminescent: Visible in
darkness conditions & at night
for Night birds & migrators.

page 11
 Innovation in HVDC applications
UNIVERSAL CONNECTOR
Integrated shielding
protection Up to 800kV

Keepers
Al. Blades

Stainless steel
fasteners Anti-rotating Single Contact Grid

Single Bolt Pivot

with reduced torque

Benefits Performances

Compact design (Reduced insulation distance)
I Nom= 4000Amps (IEC 62271-1 & NEMA CC1)

Fully Adjustable Multi-angular Connectors (+/- 45° Hor & Vert)
U Max: 800kV (p/p) – RIV: 2500μV (IEC 62271-1)

Easier & Fast to Install (No machining at Site)
Short-Circuit: 63kA/1 sec

High Performance & Reliability
Mechanical bending oscillations test:: 100 000 cycles

Heavy Duty performances (Electrical & Mechanical)
Heating cycle test: ANSI 119.4 – Class 2 (125 Cycles)

Single Bolt Pivot technology (+15 Years Experience on Field)

page 12
 Innovation in UHV substations
New 800KV Compact Design

- Developed for ANSI, NEMA, IEC and IS compliant

n
d desig
Roun
- Conductors bundle:
Quad conductors 450-457 mm spacing.

)
Size of bolts (M12
- Mechanical strengths (9070 N per cond)
ion
sect
ross
ter ial c
Ma
- Short circuit 40kA/3 sec to 80 kA/0,5 sec

ers
2 Keep
- ANSI, NEMA, IEC & IS std requirements

page 13
Innovation in UHV substations
1200kV Connectors

Clamps connectors & spacers

1200kV
- 1st experimental Project
- Bina Station (INDIA)

page 14
Innovation in UHV substations
Suspended busbar system
Suspended busbar system

Grading rings

Arcing protections
(optional)
Insulator
string
Steel suspension
structure
Al Busbar

Adjustable
attachment points

Clamp

Benefits

Long busbar span

Insulators post saving

Calculate to ensure stability in case of short circuit

Fit for seismic conditions

page 15
Innovation in advanced transmission solutions
Telescopic busbar concept

AIS

Connecting equipment of UHV

substations exposed to critical
seismic conditions. Offshore AC/DC

Connecting AC &DC power

equipments on offshore
platforms with integrated HVDC Classic
damping systems

Connecting Power Electronic

equipment in converters
exposed to seismic conditions

page 16
Innovation in advanced transmission solutions
Telescopic busbar concept

The Telescopic Busbar is an expandable rigid tube in

aluminium alloy able to work under electrical load & High
Voltage conditions in dynamic sliding modes with
relatively long displacements (1 to 1.5 meter).
Optionally, an integrated damping pneumatic function
can be added to the busbar system to self damp
connected equipments which would be submitted to low
vibrations frequencies repetitively.
Internal flex conductors

Bearings

Valve air

page 17
HV References
Experience

We are qualified by most of the contractors and utilities ww

Our key Customers

Areva – ABB – Siemens – Schneider – L&T - Mitsubishi – INEO – Cegelec – Alstom - Efacec -

AEG - Alfanar - Poxer Trading – ESBI – Fabricom – Elecam – Kahrakib – Matelec – NCC – Multidicovery

– Mahkota – Hapam – Isolux – Meepco - Sadinter Sogecomex - Nokian - Reliance – Sidelaf -

Pauwels – SLO - Hitachi – CERN – Enertrans - STEG – CGEE – Trindel - Energoinvest –

Electromontaj – RWE – Parsian – Fulmen - Fortum…

Fortum….

Utilities

RTE – PGCIL – NTPC – Sonelgaz – SCECO – Fingrid – Transelectrica – ESB - NTDC - TNB –

Edelca – IEC – PEEGT – EDP – Hydro Quebec – Iberdrola – NGT – ESB – Furnas – ENEL – CEL –

Senelec - CIE – Hydro one – Hydro Ontario …

page 18
References
Strengths & Expertise

* Solution provider to UHV Grids.

* Technical support to customers and end users

Cigre paper – Sipat 765KV project

* Innovation & new technologies.

* “SIMEL” Brand recognition very strong WW

* CIGRE members

CIGRE Exhibition 2012

page 19
References

Canada
China
UK Germany

France
India

Venezuela

400kV to 550 kV projects

765 kV projects
Australia

HVDC projects

We export in 100 countries plus ww

page 20
HVCS TECHNOLOGIES
HVCS Global
Conventional Technologies

Bolted Compressed Welded

page 22
HVCS Global
Bolted connector

Advantages Disadvantages

• Mechanical and electrical • Careful preparation

characteristics according of the conductor and
to NEMA-UTE-CEI. connector.
• Easy to install.
• Removable and re-usable.
• Widened tightening
capacity.

page 23
HVCS Global
Compressed connector

Advantages Disadvantages

• Very good • Requires a suitable press

mechanical and tooling.
resistance.
• Does not accept a mistake
during the assembly.
• Quite long to intall.
• Limited range taking of
conductors

page 24
HVCS Global
Welded connector

Advantages Disadvantages

• Very good electrical • Requires a welding

performances. equipment and an
experienced and
• Price.
skilled welder.
• Does not accept any
mistake during the
assembly.
• Important installation
time.

page 25
 HVCS Global
Key Technologies

TYPE APPLICATION

Cable
Bolted Tube
Stud
TECHNOLOGY

Crimped Cable

Cable
Welded Tube

page 26
Preliminary Technical Requirements
HVCS Global
Choice of connectors – Importance of parameters

• Country of Installation & Utility

• Required Standards (NEMA, IEC, IS…)

• Nominal Voltage (U - kV)

• Nominal Current Rating (In - kA)

• Short Circuit (Isc – kA/s)

• Conductor Details

• Apparatus terminals material & dimensions

• Layout and/or BOQ details

page 28
HVCS Global
Conventional equipments & details

Palm Stud

CIRCUIT
BREAKER disconnector
closed

DISCONNECTOR disconnector
open

page 29
HVCS Global
Common used conductors
TUBES
ALU diameter from 30 to 250 mm

CONDUCTORS
ALU (AAC - AAAC or ACSR)
cross-section from 70 to 2000 mm2

Tube dia. (mm)

SELECTION OF THE TUBE

AS A FUNCTION OF LENGTH OF SPAN F

Span lenght (m)

page 30
HVCS Global
Selection of conductors

Technical data Requirements Calculation Selection

Conditions :
- Altitude
- Air humidity
- Wind
- Icing
Service Calculation
Calculation of
of Min O/D & N°°
voltage voltage
voltage Gradient
Gradient Conductors
Layout &
conductors
Short-circuit Calculation of Min. cross section
current conductor stress + type of conductor

Calculation of Min. cross

Nominal
temperature rise section
current
of conductor
Max Temp rise

page 31
HVCS Global
Heating & expansion of the tubes

1) Temperature rise

- at nominal current (In)

t maxi of conductor = t ambient + heating at In

- at short circuit current (Isc)

t maxi of conductor = t ambient + heating In + heating Isc

2) Thermal expansion

d = k ( l x t)
d = dilatation in mm
l = tube lenght in m
t = temperature in °C
k = Thermal expansion factor
of material

page 32
QUESTIONS ?
 HVCS INDIA
PRODUCT RANGES
HVCS India
Sinemex Range – Up to 330kV

Aluminium application
Bolted type
2 keepers
Meets the requirements of NEMA CC1 1984 and 107
SIMEL NEMA EXPORT

Connection between aluminium stranded conductors & tubes

Possibility of providing 330kV bi-metallic application

Ref : Function - Material - Calibre - (Pad)

Locations : Worldwide

page 35
HVCS India
Sinemex Range – Fonctions & Material

CA - Cosse Axiale - Axial terminal

CD - Cosse Déportée - Stepped terminal
CE - Cosse Equerre - 90°° Terminal
CT - Cosse en Té - Tee terminal
T - Té - Tee
RD - Raccord Droit - Straight connector
RP - Raccord Parallèle - Parallel connector
S - Support – Support

8 Aluminium
3 Hot dip galvanised
2 Stainless steel

page 36
HVCS India
Sinemex Range – Examples

page 37
HVCS India
Sinemex Range – Examples

page 38
HVCS India
Sinemex Range – Calibers

Conductor calibres - Stranded & Solid

- 11: 08 to 11.99 mm - 25: 21 to 25.99 mm - 40: 36 to 40.99 mm

- 15: 12 to 15.99 mm - 30: 26 to 30.99 mm - 45: 41 to 45.99 mm

- 20: 16 to 20.99 mm - 35: 31 to 35.99 mm - 50 to 250 mm diameter

• Number of conductors

Code A B C D F G H J L M N P Q R S T U V
Main 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4
Tap 2 3 4 0 1 2 3 4 0 1 2 3 4 0 1 2 3 4

• Spacing

E100 : 100mm, E200: 200mm, E300: 300mm, E450: 450mm …

page 39
 HVCS India
Sinemex Range – Example Drawing
Conductor caliber Terminal details
25 - 21 to 25.99 mm Code - PCD / Pad
ø - Stud
Connexion No.
F – Main 2/Tap 1

CD 83 F 25 E200 100 C257

Shape
CD – Stepped

Material
8 – Aluminum
3 – HDG Fasteners

Subconductor spacing
E200 = 200mm

page 40
HVCS India
400kV connectors

Aluminium application
Bolted, welded or crimped
1 or 2 keepers on solid conductors
2 keepers on stranded conductors
Rigid, sliding & expansion busbar connectors & supports
Connection between aluminium stranded conductors & tubes

Possibility of providing bi-metallic application

Ref : 4 + Function - Material - Calibre - (Pad)

Locations : Worldwide

page 41
HVCS India
400kV connectors

page 42
HVCS India
400kV connectors - Fonctions

1e
C Conductor to conductor
L
Type of Conductors T Tube to tube or stud
E
T M Mixte (conductor, tube or stud)
T P Conductor to Pad
E
R Tube or stud to pad
R

2e A Axial Terminal

L D Déporté – Stepped connector

E Shape E Equerre - 90°connector
T
G Straight connector
T
E T Tee connector
R S Spacer

page 43
HVCS India
400kV connectors - Calibers

Connection type for cables :

S : Bolted
- S196: 18.0 to 19.6 mm - S300: 28.1 to 30.0 mm - S400: 38.4 to 40.0 mm
- S214: 19.7 to 21.4 mm - S322: 30.1 to 32.2 mm - S415: 40.1 to 41.5 mm
- S229: 21.5 to 22.9 mm - S335: 32.3 to 33.5 mm - S427: 41.6 to 42.7 mm
- S244: 23.0 to 24.4 mm - S350: 33.6 to 35.0 mm - S436: 42.8 to 43.6 mm
- S260: 24.5 to 26.0 mm - S361: 35.1 to 36.1 mm - S445: 43.7 to 44.5 mm
- S280: 26.1 to 28.0 mm - S383: 36.2 to 38.3 mm - S465: 44.6 to 46.5 mm

SH : Compression - SW : Welded (conductor diameter)

• Connection type for solid :

B : Bolted Stud - T : Bolted Tube - TW : Welded Tube
Solid calibres - 30 to 250 mm diameter

page 44
HVCS India
400kV connectors – Conductors & Busbars

For cable connectors:

• Number of conductors

Code A B C D F G H J L M N P Q R S T U V
Main 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4
Tap 2 3 4 0 1 2 3 4 0 1 2 3 4 0 1 2 3 4

• Spacing (in mm)

A : 50, B: 100, C: 150, D: 200, E: 250, F: 300, G: 350, H: 400, I: 450mm

For busbar connectors:

• Post Insulators base plates

P3 : 76mm – P5 : 127mm – P225 : 225mm – P7 : 178mm – P10 : 254mm

• Current bridges for expansion type connectors

26 : 2 x 604mm² - 29 : 2 x 910mm² - 46 : 4 x 604mm² - 49 : 4 x 910mm² …

page 45
HVCS India
400kV connectors – Example Drawing
Conductor details
46 – 4x604mm²
400kV Range Tube 29 – 2x910mm²
ID/OD

4 RAL 83 T97/114 R90 46

Shape
RA – Straight
L - Expansive

Material
8 – Aluminum
3 – HDG Fasteners

Terminal details
Code - PCD / Pad
ø - Stud

page 46
HVCS India
UHV Range – Up to 800kV

Aluminium application
Bolted
1 or 2 keepers on solid conductors
2 keepers on stranded conductors
Rigid, sliding & expansion busbar connectors & supports
Connection between aluminium stranded conductors or tubes
& apparatus terminals

Applications : AIS substations Worldwide.

Compliant to NEMA CC1, IEC 60 271-1, IS 5561 and ANSI 119.4 standards

page 47
 HVCS India
UHV Range – 800KV Optimized design

-Developed for NEMA, IEC and IS compliance

- Conductors bundle:
Quad conductors 450-457 mm spacing.
Rou
nd d
esig
n

- Mechanical strengths (9070 N per cond) Size of bolts (M

12)

Material section
- Short circuit 40kA/3 sec to 80 kA/0,5 sec
ers
2 Keep

- NEMA, IEC & IS std requirements

page 48
HVCS India
UHV Range – Applications - 765kV S/S – India (Sipat)

page 49
HVCS India
UHV Range – Innovation

Tap connector size spherical and cable enclosed & protected

Lower torque (60Nm vs 120Nm)

Faster to install (2 keepers)

Equivalent voltage gradient

We continuously contribute to optimize the UHV design

based on our proven experience.

page 50
HVCS India
UHV Range – Examples

page 51
 HVCS India
1200kV connectors

• Aluminium application
• Bolted type connectors
• 2 keepers on solid conductors
• 2 keepers on stranded conductors
• Rigid, sliding & expansion twin-busbar connectors & supports
• Connection between aluminium stranded conductors or tubes
& apparatus terminals (8 conductors bundle).

• Applications : UHV substations India.

• Compliant to NEMA CC1, IEC 60 271-1 & IS standards

page 52
HVCS PRODUCTS IN HALOL
TRADE / RE-EXPORT
HVCS India
Activities in Halol

Re-Export Business
Trade Business
Asian & African
Indian Market Markets
Halol Factory

page 54
 HVCS India
Requirements
Trade Business Re-Export Business

As per IS & NEMA standards As per NEMA standard

Body Material : LM6M Body Material : LM25-TF (most parts)

LM6M (spacers, PG
clamps, end cap,
Fasteners : Hot Dip Galvanized
corona bell)
Electro Galvanized

Fasteners : Stainless Steel

Surface finish : Raw from casting

Surface finish : Pad and/or sleeve

machined (Asia)
Raw from casting
(Africa)

page 55
TEST REQUIREMENTS
HVCS India
Testing

Main tests required by most of the international standards:

- Temperature Rise
- Electrical Resistance
- Mechanical/Tensile
- Short Circuit
- RIV/Corona

In India, we mainly work with test lab as ERDA and CPRI.

page 57
HVCS India
Temperature Rise
TEST
NEMA CC1 Connector t1

T°°connector < T°°conductor

t1 < t2

>1m
Conductor t2

l
IS 5561 (1970)
The temperature rise of power connector
above a reference ambient temperature of
40°°C when carrying rated current shall not
exceed 45°°C.

Nota : PGCIL requires that the temperature rise of power

connector above a reference ambient temperature of 50°°C
when carrying rated current shall not exceed 35°°C.

page 58
HVCS India
Electrical Resistance
TEST
NEMA CC1 (1984)
The electrical resistance of the connector
should not be higher than 110% of the
resistance of the reference conductor.

Rconnector < Rconductor x 1,10

1250 mm
IS 5561 (1970)
The resistance of 1.25m of a conductor,
including one connector, such as splices or
elbows, shall not exceed the resistance of the
identical conductor without connector, by more
than 10%. 1250 mm

R1 < R2 x 1,10

page 59
HVCS India
Tensile

TEST
Connector
to be tested

Mark on the
conductor

Conductor

By applying a mechanical pull-out strength onto the

conductor, the connector should not break and the
cable should not slide from the connector. F

page 60
HVCS India
Short Circuit

TEST

IEC 62271-1

Mechanical :
No crack or damage on the connector.

Thermal :
T°connector < 200°C (after testing)

IS 5561 (1970)

Mechanical :
No crack or damage on the connector.

page 61
 HVCS India
RIV / Corona
TEST
Corona : No visible discharge on the
conductor and on the connector at the
applicable voltage should appear.

RIV (Radio Interference Voltage) : The

level of radio interference should not be
greater than that specified in the applicable
standard (in µv or dB).

page 62
 HVCS CONNECTORS
TECHNICAL REQUIREMENTS
HVCS India
Connectors Requirements

Parameters Influence

 Dimensions  Mechanical Properties

 Geometry  Conductivity

 Material  Contact Resistance

 Porosity  Corona Effect

 Roughness

 Hardness

Tyco.avi

page 64
HVCS India
Connectors Requirements

Parameters Influence

 Dimensions  Mechanical Properties

 Geometry  Conductivity

 Material  Contact Resistance

 Porosity  Corona Effect

 Roughness

 Hardness

page 65
HVCS India
Connectors Requirements

Parameters Influence

 Dimensions  Mechanical Properties

 Geometry  Conductivity

 Material  Contact Resistance

 Porosity  Corona Effect

 Roughness

 Hardness BS 1490 : 1988 Tensile Strength Elongation

Sand casting Chill cast Sand casting Chill cast

Heat
Designation min. min. min. min.
Treatment
Good quality raw & N/mm² N/mm² % %
pouring material is
LM6M No 160 190 5 7
required
LM25TF Yes 230 280 - 2

page 66
HVCS India
Connectors Requirements

Parameters Influence

 Dimensions  Mechanical Properties

 Geometry  Conductivity

 Material  Contact Resistance

 Porosity  Corona Effect

 Roughness

 Hardness

page 67
HVCS India
Connectors Requirements

Parameters Influence

 Dimensions  Mechanical Properties

 Geometry  Conductivity

 Material  Contact Resistance

 Porosity  Corona Effect

 Roughness

 Hardness

page 68
HVCS India
Connectors Requirements

Parameters Influence

 Dimensions  Mechanical Properties

 Geometry  Conductivity

 Material  Contact Resistance

 Porosity  Corona Effect

 Roughness

 Hardness

page 69
HVCS India
Connector from Competition (Sangdong)

page 70
MANUFACTURING PROCESS
HVCS India
Manufacturing Process

 Aluminium sand casting

 Gravity die casting

Mash Plate

 Heat Treatment

 Finishing

Die

page 72
 HVCS India
Manufacturing Process

Sand Casting Die Casting

• Low tooling and equipment cost means that short production runs • Excellent dimensional accuracy
are viable • High casting tensile strength
Advantages

• Simple production process • Smooth cast surfaces

• Use of sand cores allows fairly complex shapes to be cast • Reduces or eliminates secondary machining operations
• Large components can be produced • Rapid production rates
• Suitable for small batch production (small production rates)
• Many material options
• Scrap can be recycled
• Short lead time possible

• Poor surface finish and tolerance • Very high capital cost

Disadvantages

• Unstable casting quality • High-fluidity metals required

• Further processing often required • Casting weights must be between 30g and 10kg.
• Not suitable for mass production • Small amount of porosity.
• Poor material strength
• High porosity possible

page 73
HVCS India
Manufacturing Process

Drilling

Aluminum Assembly
Milling Welding
QA
(if required)
Packing

Turning

page 74
CONTACT PREPARATION
Theory Of The Power Electrical Contact – Bolted connectors

Bolts (Type&Nb)
F F
 Tightening torque
 Tightening method
Conductor (type)
 Geometry
F F

Geometry of Geometry of flat surfaces

circular surfaces Contact (mathematics model)
surface

Cylindricity Flatness

Ra: Ra:
Roughness Preparation Contact Roughness
of surfaces grease

page 76
 Theory Of The Power Electrical Contact – Preparation

Metallic contacts
Al Oxide
(Dielectric
layer)

Contact not prepared Contact

prepared

The aluminium and its alloys have the property to become instantaneously oxidized in
contact with the air.

The aluminium oxide is an insulator of which the hardness is close to that of the
diamond.

page 77
 Theory Of The Power Electrical Contact – Principle

Contact principle:

Oxide Aluminum oxydes itself

Metal instantenously with
oxygen contact.

Installation procedure:

Conductor/tube & connector preparation on electrical contact side.

Breaking the oxyde layer with metallic brush & protect with Enertal Grease.

page 78
 Theory Of The Power Electrical Contact – Contact Grease

“Very hard” particles

Grease with corrosion
inhibitor  Perforate the oxide coating and increase
the tensile mechanical performances of the
 Protect the contact
connections.

“Soft” metallic particles

 Increase the number of metallic
contacts

The use of a contact grease increases the performances of the contact and protects it
from external attacks.

page 79
Theory Of The Power Electrical Contact – Holm Law

A a=S

S Rc= / 2A (Holm law)

= Material resistivity
A = Contact dimension (radius)
S = Total surface of metallic contact
page 80
Theory Of The Power Electrical Contact – Brinell Law

Rc

F = Contact pressure

F
H = Hardness of material.
F=SxH (Brinell law)
S = Contact Surface

page 81
Theory Of The Power Electrical Contact – Electrical contact preparation

To eliminate the oxides/ To improve the electrical

WHAT performances /To provide a good sealing.

WHEN During the erection time.

WHERE The electrical contacts only.

WHO The erection team.

HOW In accordance with the T.E. SIMEL specifications.

WHY To optimise and to guarantee the product performances .

page 82
Theory Of The Power Electrical Contact – Surface Finish

Technology Bolted
Bolted
contact
1/2
contact
Process flat
circular
+ Cost + Cost
+ Delivery time + Delivery time
+ Increases the contact surface + Increases the contact surface when
Raw from when using contact grease. using contact grease.
casting - Aspect (doesn’t reassure the
customer)
- Not applicable for contact grid using
- Aspect (doesn’t reassure the
customer)
+ Good aspect + Good aspect
+ Permit to easily control all - Cost
geometric parameters
- Delivery time
Machined + Permit to reduce the qty of
casting models - Give adding value
- Give adding value
- Cost
- Delivery time

page 83
QUESTIONS ?
THANK YOU.