Powerline Binder Nov1

New Zealand: Freephone: 0800 733 735 Freefax: 0800 733 736Australia: Freephone: 1800 141 502 Freefax: 1800 141 503 www.electropar.co.nz email: [email protected] November - Issue 9.2

Power Distribution Equipment The Electropar Team have you Covered!

Short Circuit TestedSubstation Busbars& Fittings

11kV - 500kV to 63kA / 1 Second

Cover Image. Substation Primary System Innovation Electropar High Voltage Underhung Busbar System Test Rig Powerlabs, Vancouver, Canada 2009

Electropar’s claim to be expert in the Power Distribution equipment arena is backed by some serious experience : the Company has been in the power line since the 1960’s!. Thanks to successful long-standing partnerships with best in class international suppliers, together with best practice R&D and manufacturing for underground and overhead distribution line and station equipment, the Electropar package is a powerful one.

Whether it’s connectors, surge protection, insulators, G&B gear, linemans tools or Arc Flash protection, the Electropar team have you covered!

PowerlineNZ November 2009.indd 1 28/10/2009 4:01:53 p.m.

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THE POWER TO PERFORM

2222222222High Voltage Underhung Busbar System Phase To Phase InsulatedSHORT CIRCUIT TESTING

PROJECT

During 2008 and 2009 Electropar has been working closely with Transmission Network Service Provider (TNSP) Transpower NZ Ltd, on a ground breaking substation project. Together, the two Company’s have embarked upon a programme to mathematically validate and then short circuit test a full size bay width of phase to phase insulated 220kV 200mm OD (4000amp) busbar and interplant connections at 25kA, 31.5kA and 40kA/3s fault levels.

On the strength of a convincing commercial argument, Transpower and Electropar desired to prove that phase to phase insulation in transmission substations is not just technically possible; it is the future of design for delivering the best value

Transmission Assets.

The commercial argument was based on the reduction in quantity of foundations/civil works in addition to shrinking the footprint of the air insulated switchyard. Financial analysis indicated that the cost saving in civil works, electrical equipment and real estate was substantial enough to warrant the investment in a development programme.

Before practical test could be considered though, the first milestone was to have the fundamental design elements examined and ratified by an independent and suitably qualified consultant.

The analysis centered around the mechanical withstand of the system and was completed by Beca Carter

(Auckland) in the third quarter of 2008. The Beca work was then peer reviewed by Maunsell prior to Christmas 2008.

Subsequently all parties agreed that the mathematical calculations indicated the system would withstand the short circuit forces generated under Transpower’s worst case fault scenario. However, to provide an additional level of confidence a finite element analysis (FEA) was completed to further verify critical load points within the system.

As a result of gaining agreement that technically the High Voltage Underhung Busbar System was feasible, Stage 2 of the project has been completed. Practical short circuit testing of the busbar system.

The testing took place at Powertech Lab’s

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New Product Releases

sampling plan.

This work is done with our own set of calibrated Go/No Go gauges, shown in the picture adjacent. The Go/No Go gauges have been calibrated with a (cmm) post manufacture, and certified as dimensionally correct to within 1000th of a millimetre.

When Electropar delivers ball and socket fittings, we don’t just say “they are correct”, we can prove it! For more information

Ever looked at a transmission or a distribution or line hardware forged or cast fitting ball or socket and thought “how do I tell if this is exactly what it should be and it is OK?!”

For some items, it is a simple matter of measurement to prove that the fitting is dimensionally acceptable. For example for a 160kN clevis, it is a case of measuring the width of the clevis and the diameter of the pin.

The fit between ball and socket fittings is equally as critical and clevis and tongue but impossible to measure on site other than by fitting the two items together for a quick physical check. However, this type of inspection will prove only that the items don’t mechanically foul one another: it won’t prove compliance with the standard that defines the size and shape of the IEC16mm and 20mm ball and socket fittings. Enter Ball and Socket Go/No Go gauges!

The principle of Go/No Go gauges is simple. If a “Go” gauge fits the item being measured, it’s OK. If a “No Go” gauge fits the item being measured, something is amiss! At Electropar, to ensure that all ex production ball and socket fittings are dimensioned in accordance with relevant standards we sample test each batch of ball and socket forgings in accordance with a

Ball & Socket GaugesScience behind Transmission Forgings Q.A.

Helical Suspension UnitsElectropar Introduces New Range

angles up to 300 and twin configuration for greater angles, the Electropar Helical Suspension Units are tested in accordance with the requirements of AS1154.

For more information contact your local Electropar office or

[email protected]

To enhance it’s competitiveness for distribution and transmission line project packages, Electropar has introduced it’s own range of Helical Suspension Units for AAC, ACSR and AAAC conductors from 13mm to 35mm.

Utilising industry standard aluminium alloy armour rods and a cast conductor clamp, the rubber insert is manufactured from ozone resistant EPDM rubber.

Available in single configuration for

contact [email protected]

Substation Primary System Innovation Electropar High Voltage Underhung Busbar System Test Rig

Powerlabs, Vancouver, Canada 2009


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Voltage Underhung Busbar System is being seriously considered for an upcoming greenfields 220kV site.

Some incredible footage of HV systems under incredible short circuit loads has been collected as a result of the testing.

This footage, and the strain data collected (1 Terabyte!) is currently undergoing detailed analysis. However, in addition to verifying the performance of the high voltage underhung busbar system, the testing has also verified the short circuit

performance of other Asset critical c o m p o n e n t s such as bus support posts, jumper/dropper connections and

rigid bus clamps and fittings.

The method of calculation for short circuit performance of these asset critical components is already the subject of a CIGRE working group as calculation methodologies have historically differed between and within designers and asset owners.The successful testing underscores the performance of Electropar’s substation

333333333333333High Voltage Underhung Busbar System Phase To Phase Insulated

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in Vancouver, Canada (http://www.powertechlabs.com) in June 2009 after a global search for laboratory’s with capability to complete this challenging scope.

At Powertech Labs, Electropar built a full bay of 220kV (see main photo) utilising Transpower’s standard cage type concrete foundations, steel support structures, post

insulators and Electropar’s rigid bus/flexible conductor fittings so that the performance of all components of the system as would be installed in a real substation can be validated.

The Electropar/Transpower project team were responsible for the measurement of the loads and displacements of the system under varying fault conditions, and used a combination of high speed camera’s, still camera’s video and fibre optic sensors for data acquisition.

In all, 85 short circuit tests were completed over a 5 day test period between 25kA/0.3s and 63kA/1sec, including long duration tests at 40kA/3s. The system performed in accordance with expectation and as a result the High

systems and at the same time introduces a new concept in HV substation design and operation.

The new concept has been successfully tested, and has the potential to significantly lower capital cost of building substation assets. It also offers a substantial reduction in maintenance costs and improves access within the switchyard.

These outcomes are achieved with a minimal loss of operational flexibility and have the potential to result a step-change for substation primary construction in NZ and Australia.

For more information contact [email protected]

NOVEL CONCEPT Andrew Renton TRANSPOWER INITIAL DESIGN Greg Barclay ELECTROPAR

QUARTER SCALE TEST ELECTROPAR Auckland Laboratory

FINAL DESIGN ELECTROPAR Engineering Department

HIGH POWER LABORATORY GLOBAL SEARCH ELECTROPAR Engineering Department

Electropar - Transmission Line Experts! Fulfilling Lines Company Needs For Over 50 Years!Electropar & Salvi Team

Creating a Powerful Transmission Line Package

Via a partnership with A. Salvi & Co or Milan, Italy, Electropar can now offer the same elegant end to end package for transmission and distribution line projects as for substations.

For some months Electropar and Salvi have been working closely together on some identifiable large projects that draw upon each organisations unique skills and competitive advantages. The Company’s are very complimentary, and the “fit” between what each operation brings to complex Transmission Line Projects has

proven to be a good one.

E l e c t r o p a r unders tands the demands of New Zealand and A u s t r a l i a n Transmission N e t w o r k S e r v i c e P r o v i d e r s (TNSP’s) and is very familiar

with the local performance requirements which are based largely on Australian Standard AS1154.

Salvi have incredible expertise at engineering customised transmission line solutions, and are arguably the world leaders in vibration control in terms of stockbridge dampers and spacer dampers technology.

Working in combination, and sharing information and partnerships in terms of global sources of supply for simple components creates a powerful commercial package to back the technical expertise.

For more information contact Cam Wallace at [email protected]

Electropar manufactures / designs or supplies the Transmission Line essentials!

• Compression Fittings • Implosive Fittings • Steel Forgings • Yoke Plates • Steel Hardware • Helical Suspension Units • Corona Rings • Armour Rods • Earthwire Assembly’s • OPGW Assembly’s • Spacer Dampers• Stockbridge Dampers• Polymer Longrod Insulators• Porcelain Disk Insulators• Glass Disk Insulators

AAC, ACSR, AAACAAC, ACSR, AAACHDG & compliant with Charpy Notch TestHDG for twin, tripe, Quad bundlesExtension Links, plate links, sag linksAAC, ACSR, AAACAluminium AlloyAluminium AlloySuspension and DeadendSuspension and Deadend

STRAIN TOWER FITTINGS

SUSPENSION TOWER FITTINGS


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44444Western Development Project NSW 500kV Substation Case StudyTransGrid 500kV

InvestmentDelivered by United Group Ltd

and Electropar

New South Wales Transmission Service Provider (TNSP) TransGrid has continued to invest heavily in development of its 500/330kV Substation Assets over 2007/2008/2009.

Early in 2007 United Group Infrastructure were awarded an important Design and Construct contract to build four large 500/330kV substations at the Bayswater, Mt Piper, Bannaby and Wollar sites.

This capital works project scope known as the “Western 500kV Development” is one of the largest ever seen in Australia, and is a combination of augmenting existing 330kV stations and construction of new Greenfield’s 500/330kV substation sites.

In turn, United Group Infrastructure awarded Electropar an initial contract for all of the 500/330kV tubular bus, strung bus and interplant equipment conductor

fittings for Bayswater and Mt Piper in June 2007. Identical primary scopes for Bannaby and Wollar were then awarded by United Group Infrastructure to Electropar in 2008.

Not only have these four projects been some of the largest ever completed by United Group Infrastructure and Electropar, they have also been some of the most technically complex. A large number of new components and assembly’s have been developed for the works and to substantiate their performance RIV testing at CSIRO in Sydney and electrical type testing to

IEC 61284 at Electropar’s independently accredited high current lab has been completed

Other components and assembly’s used at Bayswater, Mt Piper, Bannaby and Wollar have utilised Intellectual Property from TransGrid’s existing catalogue of 500kV components and assembly’s.

The combination approach to test new assembly’s and rely on TransGrid’s existing 500kV in service experience has been a successful one designed by United Group Infrastructure around engineering best practice for delivering EHV assets.

Electropar is delighted to have played a part in the development of these critical assets for the NSW transmission network alongside United Group Infrastructure.

Electropar CEO Grant Wallace comments that “Electropar has learned a great deal from the 500/330kV work completed in NSW with United Group Infrastructure for TransGrid, and the contract has lifted our

game in many facets of our business including design, testing and product traceability from source material.

The team is very proud to have been involved.

The Bayswater and Mt Piper sites are now energised with Bannaby well progressed in terms of construction and Wollar at 50% civil works stage. Both Bannaby and Wollar will be completed by United Group later in 2009.


Ashburton 220kV UpgradeTwizel (TWZ) to Timaru (TIM), then to Ashburton and finally to Islington (ISL) and Bromley (BRY) substations in Christchurch. The project removed this contingency by bussing the second ISL-TIM-TWZ circuit. In order to meet a Grid Reliability Standards requirement to allow for a failure of a bus coupler breaker, a third bus section was also required.

Augmenting the Ashburton site was a tricky proposition as the substation carries a heavy irrigation load for Canterbury’s dairy industry, with a summer peak. Due to operational constraints, the majority of outages were undertaken during weekend or holiday weekends over the 12 month period. Practically, the scope involved extending the switchyard to the west replacing 2 towers in the process, together with disconnection of all existing line circuits in combination with establishing new connections and maintaining

supply at all times. Post re-enforcement the site now has four 220kV line connections and is configured in an H Bus arrangement (compact) with staggered bus couplers.

A feature of the Ashburton project was the 3D CAD draughting of the site completed by Transpowers Design Service Provider AECOM. Luke Crowe at AECOM NZ Ltd started applying 3D CAD work in 1995 and now apply the 3D techniques to all T&D projects. Principal at AECOM’s Wellington office Don Wills comments that “3D is a highly productive and powerful tool, as it addresses the design principles of visualization, presentation, and verification. It ensures constructability, allowing the Suppliers, Contractors and Clients to see what’s proposed, and to contribute their ideas before sign-off. We

get very positive feedback from them!” Don also notes that “it also addresses Safety by Design, as it allows everyone to review the design from the different perspectives of Construction, Construction sequence, Maintenance and Operation”.

Electropar’s role in the Ashburton project was manufacture and supply of the tubular aluminium busbars and fittings together with fittings for all interplant connections. This included specially designed connections for the bus end connection of the pantograph disconnectors and a customised bipod arrangement to accommodate back to back feeder from an existing main bus. The system was supplied to site so that it simply bolted together without site welding. The 3D drawings supplied courtesy of AECOM and Transpower detailing the Ashburton site configuration have been overlaid with photos taken of the site where available, and with 3D images of Electropar fittings created by AECOM as part of the process.

For more information contact [email protected] or at AECOM Don Wills on [email protected]

Tubular Aluminium Busbar

Fixed Busbar Support

Busbar Support & Compression Terminals

Compression Terminals


Tee Joint

Conductor Spacers

Busbar & Flexibiles

Substation Isometric Drawings By AECOM


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55555Ashburton 220kV UpgradeElectropar Adds Shearbolts to

Utility Market Offering

Electropar is pleased to announce that the Company has been appointed exclusive distributors for Shearbolt connectors manufactured by Nexans (GPH) of Germany. Competitively priced LV and MV shear bolt terminal and connectors for 16mm2 to 630mm2 Aluminium conductor and 10mm2 to 500mm2 Copper conductor will shortly be available from Electropar’s inventory in Auckland/Wellington and Christchurch.

All connectors and terminals stocked at Electropar are water blocked with a tinned surface finish.

The products stocked for both joints and terminals have the following range taking ability (note that the same connector can be used on Copper and Aluminium

Conductors)** Items designated can also be utilised

in 11kV and 22kV cable joints

Commercially, the benefit of a range taking shearbolt fitting is that a smaller number of stock items will provide a very wide range of coverage for LV / MV conductors.

Networks that have a mixture of old imperial and modern metric conductors within their underground cable network can be especially advantaged.

Application of Shearbolts DOES require Intelligence!

An important issue for Network Engineers to understand is that correct conductor compression must take place within shearbolt connector. The GPH shearbolt connectors and terminals are a Second Generation development of the technology.

The First Generation relied on a single torque shear. This was found to overcompress small conductors, yet leave large conductors largely un-compressed, within the specified range taking for a fitting.

The Second Generation technology introduces multiple torque shear for perfect installation on every conductor within the range of the connector. This is achieved by use of an advanced design of shear bolt that still uses standard tools.

Each fitting is packed with step by step instructions, providing the correct selection tool selection : an 6mm or 8mm Allen Key or a 13mm or 17mm socket, against the conductor size and type. Figure 1 demonstrates the multiple torque shear concept.

55555Shear Bolt Connectors - GPHThe Electropar Shearbolt Range of Links & Lugs Transpower Ashburton

GXP Re-Enforcement

New Zealand Transmission Network Service Provider (TNSP) Transpower New Zealand Ltd, together with AECOM and Transfield Services have executed a complex substation re-enforcement project at the important Ashburton Grid Exit Point (GXP). The project is a fast tracked brownfields initiative, completed in just 12 months. It has included a complex outage methodology, and close co-ordination between Transpower’s system planners, electricity generators, installation contractor and customers.

Prior to re-enforcement, the existing system configuration had one circuit of the double circuit CCH - TWZ 220kV line connected into Ashburton substation by an in-out loop. The loss of the 220 kV ASB-TIM-TWZ circuit is the worst n-1 contingency, as the load at Bromley and Ashburton substations must then be supplied from Islington substation by three remaining 220 kV circuits from the Waitaki Valley. The 220kV backbone that incorporates the Ashburton (ASB) site runs from

Flexible Bus Tubular Aluminium Busbar

Welded Busbar End Terminal

Sliding Busbar Support

Compression Terminals Midspan Bolted Busbar Splice

Bolted Run Tee Connector

Post Mounted Conductor Support

90o Busbar Support

Strung Bus

Busbar Welded Terminal

Conductor Earth Point

Shearbolt FittingsRange Taking Ability for Copper and

Aluminium ConductorsGPH Shearbolt

Joints and Terminal Lugs will suit Aluminium Conductors as

follows

GPH Shearbolt Joints and Terminal

Lugs will suit Copper

Conductors as follows

16 to 35mm2 10 to 25mm2

25 to 95mm2 25 to 95mm2

35 to 185mm2 25 to 150mm2

120 to 240mm2 120 to 185mm2

120 to 300mm2** 120 to 185mm2**

400 to 630mm2** 400 to 150mm2**

Figure 2: GPH Multiple Torque Shear Concept for 95mm2 – 240mm2 Copper

Terminal

Each connector is packed with coloured spacers which should be used with smaller conductors to ensure the conductor is concentric within the connector complete with pictorial selection instructions.

All individual sizes in the GPH product range have been tested under the International Standard IEC/EN 61238-1. Electropar will be pleased to provide copies of tests for all the GPH products upon request.

For more information, contact your local Electropar Sales Office

For more information, contact: [email protected]

Figure 1: Stock Standard Item 95-185mm2 Copper Shearbolt Terminal


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New Switch 1

New Switch 2

New Switch 3

New Switch 4

New Switch 5

Team 1

Team 4

Team 2

Team 5Team 6

Team 7

Team 3

Team 8

IntelliTEAM II is Scalable – Start as Big or Small as you like!Powerco have welcomed the opportunity for a pilot to be established so that the principle and operation can be proven within the Network. IntelliTEAM II can work in minor loop control schemes with just a few switches or grow limitlessly as new teams are added to communicate with existing ones.

Whatever is installed now, can be utilised to widen the scope for IntelliTEAM II in the future. One North American utility began with just a few switch points. Today they have over 600 switch points using IntelliTEAM II.

Find out how IntelliTEAM II will benefit Your NetworkThe Electropar Team has put together an interactive CD with comprehensive information on IntelliTEAM II; this includes Case Studies such as a presentation made by Enmax of Calgary, Canada giving their own experience of IntelliTeam II for a North American Smart Grid seminar during 2008.

If you would like a free copy of this CD, please ask Chris Burbridge at

[email protected]

& CT’s, thereby having instantaneous power demand knowledge. In the event of a feeder failure, IntelliTEAM II is able to rearrange normally open/normally closed

points, to supply all but the affected line segment, within 60 seconds. It is smart enough to know limitations on how much current each Team can gain from alternative sources and which customers have priority of supply.

IntelliTEAM II works independently of SCADA, but communicates with SCADA and can be overridden by the SCADA controller. Unlike a human controller though, it can optimize alternative supply configurations within seconds and in times of crisis can handle multiple simultaneous faults.

Peer to Peer Communication: SpeedNet for SmartGrid & AMIFor IntelliTEAM II systems in NZ, Electropar is utilising the latest high speed S&C SpeedNet Radio communication device, which operates in the 921 to 928kHz public bandwidth. SpeedNet provides

6666666666The S&C IntelliRupter ® PulseCloser The Next Generation Distribution SwitchgearThe S&C IntelliRupter PulseCloser

Fault Testing with a Pulse ….instead of a BANG!

The launch of S&C’s IntelliRupter Pulsecloser has stimulated an interesting discussion between Engineers in NZ Power Distribution Companies about the damage done by reclosers, re-transmitting large fault currents on to their Networks.

There is anecdotal evidence that suggests overhead line conductors do clash under violent fault conditions and damage occurs to important network equipment in the vicinity of the fault as well as at zone substations.

General agreement exists around the fact that the biggest risk is damage to polemount, padmount and zone substation transformers

S&C Electric has developed a new technology that supersedes

reclosing:“PulseClosing™ Technology”. The equipment that delivers the PulseClosing Technology is called the S&C IntelliRupter.

The secret of the IntelliRupter lies in a new magnetic actuator design that closes the device precisely point on wave, to give a 5 millisecond current pulse for testing of fault conditions.

With IntelliRupter’s PulseClosing technology fault I2t let-through is typically less than 2% compared to a conventional reclose. The wave forms in Figures 1 and 2 show the difference between PulseClosing Technology and reclosing.

How Does The IntelliRupter PulseClosing Technology Work?Figure 2 shows the current pulse generated by PulseClosing. This pulse is analyzed by IntelliRupter’s integrated Control Module using IntelliRupter’s unique PulseClosing Algorithm. The algorithm determines from the current pulse if the circuit is faulted. If a fault is detected the IntelliRupter remains open and resumes timing or goes to lockout. Otherwise IntelliRupter closes to restore service.

Using a Monte Carlo analysis the PulseClosing Algorithm was determined to be 99% accurate. The analysis included more than 40,000 cases, varying over 30 power system characteristics. Test parameters included substation transformer size, voltage, grounding, line segment length, overhead vs. underground, fault current, location, persistence, and load characteristics. The 1% where the algorithm cannot conclusively determine if a fault exists occurs when the fault currents coincide with high load currents. In these cases IntelliRupter will close with the energy let-through being very close to that of the load.

Easy Up Easy On!IntelliRupter has its own power source and inbuilt control and communication modules.

It does not need a separate 240V transformer, control box and lots of electrical spaghetti! Figure 3 shows an IntelliRupter with factory installed surge arrestors and an interlocked disconnect that provide a visual break for the linestaff working around the device.

After initial installation, the Modules for

S&C’s IntelliTeam II ®

The Ultimate Self Healing Network

a secure network using spread spectrum frequency hopping technology developed for the US military and other security measures. It is used as an IP addressable device for communication between IED’s or to/from the SCADA control room. SpeedNet enables peer-to-peer communication between IED”s and also with the zone substation. From the zone substation, data is returned to the master station by RTU or fibre if available

SpeedNet’s high speed and low latency provide unmatched bandwidth in an unlicensed radio. SpeedNet also includes priority messaging to ensure critical data get through as fast as possible. The highest priority is for IntelliTEAM automation use; for decision making in times of crisis, this channel will be given priority. The other priority levels can be used for “smart metering” or AMI data allowing SpeedNet to can be used for the communication backbone supplying or backhauling information to/from smart meter networks.

Figure 3.IntelliRupter with integralinterlocked disconnects

Conventional reclosing in response to a permanent fault.

Pulseclosing in response to a permanent fault. The opposite-polarity pulse detects magnetizing inrush current; if the transformer is not faulted, IntelliRupter closes.

Figure 1.

Figure 2.

Figure 4: Powerco IntelliTEAM Stage 2: Bell Block

Figure 5: SpeedNet Radio Module

Figure 6: SpeedNet Pole Top Repeater Unit


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Whereas conventional loop systems require the tie device to lockout on the first trip to avoid multiple sags for the fault shown in figure 5, it may be beneficial to issue additional PulseCloses over a period of time to give the fault a longer chance to disappear.

The addional PulseCloses detect if the fault is still present without causing any further line disturbances. At the end of the sequence, if the fault persists, the tie device locks out without ever having closed into the fault or disturbing the unfaulted feeder.

If the fault is cleared at any time during the test squence, the tie device closes in and further reconfiguration can proceed as usual.

The rest of the loop system setup and operational characteristics remain the same as for a conventional loop.

Stage 2: PulseClosing the Entire LoopIn the Stage 1 case, careful co-ordination

Control, Communications and Battery Back Up, are all hot-stick removable for maintenance back in the depot if required. In the field, reconfiguration of the IntelliRupter settings can be completed via a wireless connection with a PC. The communications and control module need not be removed for this purpose.

Application Example #1: IntelliRupter as the Tie Point for Looped 11kV Distribution FeederStage 1: PulseClosing at the Tie PointApplying an IntelliRupter PulseCloser as the tie point in an otherwise conventional recloser loop system addresses the number one complaint about loop systems since the tie device will no longer reclose to test for faults. Upon loss of voltage on either side of the tie, a timer is started. When the timer expires, a PulseClose is issued to test the line.

77777The S&C IntelliRupter ® PulseCloser The Next Generation Distribution Switchgear

able to demonstrate the effects of automatic backfeeding on SAIFI & SAIDI performance. All IntelliTEAM II IED’s utilize DNP 3.0 serial communication protocol and this is the main criteria for selection of suitability of non S&C devices for transformation to an IED status through an S&C UIM.

With limitless automatic control ability via the UIM, extra switching points can provide both extra sectionalizing and backfeeding capability to the unfaulted line sections.

How will the Network Segment be made to perform?Powerco selected two main feeders from Substation Circuit Breakers CB2 and CB8 seen as segments Bell Block 2 & Bell Block 8 in Figure 4. The insertion of new switch points, which had been positioned for maximum effect using the Reliability Analysis Software, can be seen for the two stages. For the Bell Block 8 feeder, we have shown how the line has been divided into “Teams”.

IntelliTEAM II: Now there is an “I” in Team!A “Team” is a line segment bounded by IntelliTEAM II enabled devices. Each “Team” has a “Coach”. Each “Coach” is essentially a software agent that can communicate with neighbouring “Team Coaches” and through them, all the “Teams” on the feeder. Each Coach can determine voltage status and ability to share excess capacity from alternative sources, through the other “Coaches”, back to its own “Team”.

Each IED is equipped with 3-phase VT’s

IntelliTEAM IIState of the Art SMARTGRID

The S&C Electric Company’s IntelliTEAM II Automatic Restoration System is the world’s only self-healing, scalable, distributed-intelligence-based fault isolation & reconfiguration system. Electropar is working on pilot projects with two NZ Power Distribution Companies that plan to incorporate IntelliTEAM II into their Smartgrid vision. One of those Companies is Powerco (New Plymouth) where Ken Pattie and his team are planning to use IntelliTEAM II to dramatically improve their SAIDI and SAIFI performance at Bell Block.

Case Study : SAIDI & SAIFI Improvement at Powerco’s Bell Block Segment

Powerco nominated a segment of the Powerco Network at Bell Block in Taranaki, as they considered this area would be a good test of the IntelliTEAM II system to resolve long standing issues with SAIDI & SAIFI values.

In recent years traditional distribution reclosers had been added to the Bell Block network segment and the effect of these on SAIDI and SAIFI in terms of improved sectionalising of faulted sections

is illustrated in Figures 1 and 2. Electropar calculated the SAIDI and SAIFI values in Figs 1 & 2 for Bell Block by analyzing network data (line segment length, number of customers on each segment, location of existing devices etc) provided by Powerco. The analysis was based on a two stage roll out of the IntelliTEAM II solution.

S&C’s IntelliTEAM II Automatic Restoration System has been proven in many North American Networks, with over one hundred different customers and thousands of switching points worldwide, with a proven history of SAIDI and SAIFI reduction. Effectively, based on network configuration the S&C Electric’s Reliability Analysis demonstrates how the “biggest bang for buck” is achieved by deploying traditional Distribution Automation technologies as well as IntelliTEAM II / SmartGrid solutions. The Bell Block segment turned out to be an ideal candidate for IntelliTEAM II because of the backfeeding opportunities that IntelliTEAM II could automatically initiate and complete within 60 seconds. Hence the dramatic SAIFI & SAIDI results.

Existing Switching Equipment can be part of IntelliTeam

Reclosers cannot provide automated backfeeding by themselves. Whilst S&C has moved past this technology to PulseClosing (with S&C’s IntelliRupter), existing reclosers can be transformed into Intelligent Electronic Devices (IED’s) by the use of the S&C Universal Interface Module (UIM). By introducing UIM’s to existing automated switches or reclosers, together with some new IntelliRupters with built in IntelliTEAM II smart technology, Electropar has been

S&C’s IntelliTEAM II ®

The Ultimate Self-Healing Network

of reclosers is required and feeder A will see multiple voltage sags from the operation of A2.

In stage 2 all reclosers can be replaced with IntelliRupter. Feeder A will see no voltage sags beyond the initial fault and the line can be tested several times without disturbance to either feeder.

Electropar Has The Answers!The S&C IntelliRupter is suitable for NZ, 11kV and 22kV systems. A 33kV 50Hz model is under development.

IntelliRupters have 3-pole vacuum interrupters rated at 630 Amps continuous and 12.5kA fault interrupting capability.

Electropar is now specifying IntelliRupters with the smart IntelliTEAM II® Control option, and SpeedNetTM peer-to-peer radios, for IntelliTEAM II Distributed Automation projects that are being proposed for a number of NZ Distribution Networks.

For a detailed explanation of the IntelliRupter in loop control and more complex scenarios, refer to the Electropar “Network Automation” CD, available free from Electropar or contact Chris Burbridge on [email protected].

Reliability - STAGE 1 - Existing Feeders with Nova Recloser and Backfeed CX Switch, all Fitted With IntelliTEAM ControllersReliability - STAGE 2 - Existing Feeders with Nova Recloser and Backfeed CX Switch

and Additional Sectionalising CX Switch, all Fitted With IntelliTEAM Controllers

MTTR 300 minutes ONLY MAKE ADJUSTMENTS TO THESE VARIABLES ON THIS SHEETSAIFI SAIDI SAIFI SAIDI SAIFI SAIDI Segments SAIFI SAIDI Segments MTTS 180 minutes OTHER SHEETS ARE LINKED TO THIS ONE

Bell Block CB2 15.64 3764 11.26 2976 7.91 2372 2 3.95 1186 4Bell Block CB8 17.23 4144 12.45 3284 8.69 2608 2 4.29 1287 4

ALL 16.37 3939 11.81 3118 8.27 2480 4.11 1232

* Without DA or Reclosers - Feeders just fitted with manual switches.

* With Current Recl Deployment (EXISTING SITE) - Each feeder fitted with an existing recloser.

* With IntelliTEAM II (PROPOSED STAGE 1) - Existing reclosers fitted with UIM and IntelliTEAM IIadditional CX switches with IntelliTEAM II fitted along the feeder for automatic backfeeding.

* With IntelliTEAM II (PROPOSED STAGE 2) - Existing reclosers fitted with UIM and IntelliTEAM II, additional CX switches with IntelliTEAM II fitted (breaking feeders into 4 segments)additional CX switches with IntelliTEAM II fitted along the feeder for automatic backfeeding.

With IntelliTEAM IIStage 1


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Figure 1: Bell Block SAIFI Analysis with Deployment of Reclosers and IntelliTEAM II


Figure 3: S&C Universal Interface Module (UIM)

Figure 5: IntelliRupter Application At Tie Point

Figure 4: 11kV IntelliRupter Fitted With Distribution Class Surge Arrestors

Figure 6: IntelliRupter Communication & Control Module

Being Removed

PulseClosing Device

Reclosing Device


Grafoplast®



Queensland

New South Wales

Victoria

Tasmania

South Australia

Northern Territory

Western Australia

Queensland Algester SubstationBagara SubstationBelgian Gardens SybstationBlack River SubstationDaandine SubstationFishermans Bend SubstationGladstone North SubstationGlenella SubstationGoodna SubstationGreenbank SubstationGreenbank Substation Exten.Hail Creek SubstationKearneys SpringsKing Creek Substation

New South WalesArmidale SVC SubstationBairnsdale Substation Bannaby SubstationBayswater SubstationBlacktown SubstationCadia Substation BusColongra SubstationGreen Square SubstationHunter River Pumping StnMt Piper SubstationMullimbimby SubstationRoselle SubstationTerranora SubstationWollar SubstationYass Substation

VictoriaRowville Substation BusDandenong Valley SubstationRowville SubstationLoy Yang SubstationDederang SubstationAltona SubstationSouth Moorang SubstationMoorabool SubstationCamberwell SubstationDandenong Valley SubstationWaddamanna SubstationBurnie SubstationCranbourne Terminal StationEildon SubstationAltona SubstationMt Beauty SubstationCranbourne SubstationRowville SubstationLoy Yang Substation (Bay 14)Cranbourne (Bay A)Redcliffs SubstationKermandie Substation Altona SubstationWodonga Substation

VictoriaBaranawartha SubstationDromana SubstationBallarat SubstationShepparton SubstationMt Beauty SubstationBendigo SubstationRowville SubstationTerang SubstationRedcliffs SubstationMalvern Terminal StationHorsham Terminal StationRowville SubstationEast Rowville Terminal StationRingwood SubstationMoorabool SubstationEast Burwood SubstationMoorabool SubstationSouth MorangDoreen SubstationWaubra SubstationJeeralang SubstationMt Beauty SubstationKeilor Terminal StationSouth Morang Terminal Stn

Western AustraliaLandwehr SubstationWagerup SubstationYandicoogina Substation

TasmaniaGeorgetown SubstationMowbray SubstationSheffield SubstationZeehan Substation

Queensland Loganlea SubstationLytton SubstationOoonoonba SubstationPalmwoods SubstationPoint Curtis SubstationPoint Vernon SubstationPostmans Ridge SubstationRocky Street SubstationStony Creek SubstationStrathmore SubstationSunrise SubstationTeebar SubstationWoolooga Substation

Electropar Australasian Substation Projects 1999 - 2009“Australasia’s Power Comes From Electropar’s Substation Interconnection Systems!”

NZ SubstationAlbany SubstationAlbany Substation Arapuni SubstationBromley SubstationCromwell SubstationHenderson SubstationHuapai SubstationHuntly SubstationHuntly SubstationIslington / Kikiwa SubstationIslington SubstationIslington Substation SVC BusKaitimako SubstationKiapoi SubstationKiwi Dairy Company BusMangere SubstationMokai SubstationOhinewai SubstationOtahuhu Power Station BusPakuranga Substation BusPoihipi Rd Substation BusTuai Power StationTuai SubstationWaiotahi SubstationWairakei SubstationWairakei SubstationWairau Rd SubstationWhangamata Substation

Details220kV Substation Bus and Fittings20kV SVC Busbar System (Nokian)110kV Bus System11kV tertiary Bus System220kV Bus System220kV Bus System220kV Bus System220kV Bus System220kV Bus Extension220kV Substation Bus and Fittings220kV Substation Bus and Fittings220kV Bus System110kV Substation System110kV Busbar and Fittings110kV Bus System33kV Bus System110kV Bus System220kV Bus System220kV Bus System110kV Bus System110kV Bus System110kV Bus System110kV Bus System220kV Bus System220kV Bus System220kV Substation Bus and Fittings33kV Bus System66kV Bus System

Electropar NZ Projects Last 5 Years

South AustraliaCherry Gardens SubstationHappy Valley SubstationLe Fevre SubstationMakota SubstationNorthfield SubstationOlympic Dam (1999)Olympic Dam (2008) P3C SubstationPenola West SubstationPortland SubstationProminent HillRoseworthy SubstationSnowtown SubstationTorrens Island North Sub StnTorrens Island Power StnTungkillo Substation

NZ & OZ.indd 1 24/08/2009 12:40:50 p.m.



Substation Primary System Innovation

Electropar High Voltage Underhung Busbar SystemTest Rig, Powerlabs, Vancouver, Canada 2009


Grafoplast®



Whereas conventional loop systems require the tie device to lockout on the first trip to avoid multiple sags for the fault shown in figure 5, it may be beneficial to issue additional PulseCloses over a period of time to give the fault a longer chance to disappear.

The addional PulseCloses detect if the fault is still present without causing any further line disturbances. At the end of the sequence, if the fault persists, the tie device locks out without ever having closed into the fault or disturbing the unfaulted feeder.

If the fault is cleared at any time during the test squence, the tie device closes in and further reconfiguration can proceed as usual.

The rest of the loop system setup and operational characteristics remain the same as for a conventional loop.

Stage 2: PulseClosing the Entire LoopIn the Stage 1 case, careful co-ordination

Control, Communications and Battery Back Up, are all hot-stick removable for maintenance back in the depot if required. In the field, reconfiguration of the IntelliRupter settings can be completed via a wireless connection with a PC. The communications and control module need not be removed for this purpose.

Application Example #1: IntelliRupter as the Tie Point for Looped 11kV Distribution FeederStage 1: PulseClosing at the Tie PointApplying an IntelliRupter PulseCloser as the tie point in an otherwise conventional recloser loop system addresses the number one complaint about loop systems since the tie device will no longer reclose to test for faults. Upon loss of voltage on either side of the tie, a timer is started. When the timer expires, a PulseClose is issued to test the line.

The S&C IntelliRupter ® PulseCloser The Next Generation Distribution Switchgear

1010101010able to demonstrate the effects of automatic backfeeding on SAIFI & SAIDI performance. All IntelliTEAM II IED’s utilize DNP 3.0 serial communication protocol and this is the main criteria for selection of suitability of non S&C devices for transformation to an IED status through an S&C UIM.

With limitless automatic control ability via the UIM, extra switching points can provide both extra sectionalizing and backfeeding capability to the unfaulted line sections.

How will the Network Segment be made to perform?Powerco selected two main feeders from Substation Circuit Breakers CB2 and CB8 seen as segments Bell Block 2 & Bell Block 8 in Figure 4. The insertion of new switch points, which had been positioned for maximum effect using the Reliability Analysis Software, can be seen for the two stages. For the Bell Block 8 feeder, we have shown how the line has been divided into “Teams”.

IntelliTEAM II: Now there is an “I” in Team!A “Team” is a line segment bounded by IntelliTEAM II enabled devices. Each “Team” has a “Coach”. Each “Coach” is essentially a software agent that can communicate with neighbouring “Team Coaches” and through them, all the “Teams” on the feeder. Each Coach can determine voltage status and ability to share excess capacity from alternative sources, through the other “Coaches”, back to its own “Team”.

Each IED is equipped with 3-phase VT’s

IntelliTEAM IIState of the Art SMARTGRID

The S&C Electric Company’s IntelliTEAM II Automatic Restoration System is the world’s only self-healing, scalable, distributed-intelligence-based fault isolation & reconfiguration system. Electropar is working on pilot projects with two NZ Power Distribution Companies that plan to incorporate IntelliTEAM II into their Smartgrid vision. One of those Companies is Powerco (New Plymouth) where Ken Pattie and his team are planning to use IntelliTEAM II to dramatically improve their SAIDI and SAIFI performance at Bell Block.

Case Study : SAIDI & SAIFI Improvement at Powerco’s Bell Block Segment

Powerco nominated a segment of the Powerco Network at Bell Block in Taranaki, as they considered this area would be a good test of the IntelliTEAM II system to resolve long standing issues with SAIDI & SAIFI values.

In recent years traditional distribution reclosers had been added to the Bell Block network segment and the effect of these on SAIDI and SAIFI in terms of improved sectionalising of faulted sections

is illustrated in Figures 1 and 2. Electropar calculated the SAIDI and SAIFI values in Figs 1 & 2 for Bell Block by analyzing network data (line segment length, number of customers on each segment, location of existing devices etc) provided by Powerco. The analysis was based on a two stage roll out of the IntelliTEAM II solution.

S&C’s IntelliTEAM II Automatic Restoration System has been proven in many North American Networks, with over one hundred different customers and thousands of switching points worldwide, with a proven history of SAIDI and SAIFI reduction. Effectively, based on network configuration the S&C Electric’s Reliability Analysis demonstrates how the “biggest bang for buck” is achieved by deploying traditional Distribution Automation technologies as well as IntelliTEAM II / SmartGrid solutions. The Bell Block segment turned out to be an ideal candidate for IntelliTEAM II because of the backfeeding opportunities that IntelliTEAM II could automatically initiate and complete within 60 seconds. Hence the dramatic SAIFI & SAIDI results.

Existing Switching Equipment can be part of IntelliTeam

Reclosers cannot provide automated backfeeding by themselves. Whilst S&C has moved past this technology to PulseClosing (with S&C’s IntelliRupter), existing reclosers can be transformed into Intelligent Electronic Devices (IED’s) by the use of the S&C Universal Interface Module (UIM). By introducing UIM’s to existing automated switches or reclosers, together with some new IntelliRupters with built in IntelliTEAM II smart technology, Electropar has been

S&C’s IntelliTEAM II ®

The Ultimate Self-Healing Network

of reclosers is required and feeder A will see multiple voltage sags from the operation of A2.

In stage 2 all reclosers can be replaced with IntelliRupter. Feeder A will see no voltage sags beyond the initial fault and the line can be tested several times without disturbance to either feeder.

Electropar Has The Answers!The S&C IntelliRupter is suitable for NZ, 11kV and 22kV systems. A 33kV 50Hz model is under development.

IntelliRupters have 3-pole vacuum interrupters rated at 630 Amps continuous and 12.5kA fault interrupting capability.

Electropar is now specifying IntelliRupters with the smart IntelliTEAM II® Control option, and SpeedNetTM peer-to-peer radios, for IntelliTEAM II Distributed Automation projects that are being proposed for a number of NZ Distribution Networks.

For a detailed explanation of the IntelliRupter in loop control and more complex scenarios, refer to the Electropar “Network Automation” CD, available free from Electropar or contact Chris Burbridge on [email protected].





ALL 16.37 3939 11.81 3118 8.27 2480 4.11 1232







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Figure 3: S&C Universal Interface Module (UIM)

Figure 5: IntelliRupter Application At Tie Point

Figure 4: 11kV IntelliRupter Fitted With Distribution Class Surge Arrestors

Figure 6: IntelliRupter Communication & Control Module

Being Removed

PulseClosing Device

Reclosing Device


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STAGE 2

86296 299

190

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IntelliTEAM II is Scalable – Start as Big or Small as you like!Powerco have welcomed the opportunity for a pilot to be established so that the principle and operation can be proven within the Network. IntelliTEAM II can work in minor loop control schemes with just a few switches or grow limitlessly as new teams are added to communicate with existing ones.

Whatever is installed now, can be utilised to widen the scope for IntelliTEAM II in the future. One North American utility began with just a few switch points. Today they have over 600 switch points using IntelliTEAM II.

Find out how IntelliTEAM II will benefit Your NetworkThe Electropar Team has put together an interactive CD with comprehensive information on IntelliTEAM II; this includes Case Studies such as a presentation made by Enmax of Calgary, Canada giving their own experience of IntelliTeam II for a North American Smart Grid seminar during 2008.

If you would like a free copy of this CD, please ask Chris Burbridge at

[email protected]

& CT’s, thereby having instantaneous power demand knowledge. In the event of a feeder failure, IntelliTEAM II is able to rearrange normally open/normally closed

points, to supply all but the affected line segment, within 60 seconds. It is smart enough to know limitations on how much current each Team can gain from alternative sources and which customers have priority of supply.

IntelliTEAM II works independently of SCADA, but communicates with SCADA and can be overridden by the SCADA controller. Unlike a human controller though, it can optimize alternative supply configurations within seconds and in times of crisis can handle multiple simultaneous faults.

Peer to Peer Communication: SpeedNet for SmartGrid & AMIFor IntelliTEAM II systems in NZ, Electropar is utilising the latest high speed S&C SpeedNet Radio communication device, which operates in the 921 to 928kHz public bandwidth. SpeedNet provides

The S&C IntelliRupter ® PulseCloser The Next Generation Distribution SwitchgearThe S&C IntelliRupter PulseCloser

Fault Testing with a Pulse ….instead of a BANG!

The launch of S&C’s IntelliRupter Pulsecloser has stimulated an interesting discussion between Engineers in NZ Power Distribution Companies about the damage done by reclosers, re-transmitting large fault currents on to their Networks.

There is anecdotal evidence that suggests overhead line conductors do clash under violent fault conditions and damage occurs to important network equipment in the vicinity of the fault as well as at zone substations.

General agreement exists around the fact that the biggest risk is damage to polemount, padmount and zone substation transformers

S&C Electric has developed a new technology that supersedes

reclosing:“PulseClosing™ Technology”. The equipment that delivers the PulseClosing Technology is called the S&C IntelliRupter.

The secret of the IntelliRupter lies in a new magnetic actuator design that closes the device precisely point on wave, to give a 5 millisecond current pulse for testing of fault conditions.

With IntelliRupter’s PulseClosing technology fault I2t let-through is typically less than 2% compared to a conventional reclose. The wave forms in Figures 1 and 2 show the difference between PulseClosing Technology and reclosing.

How Does The IntelliRupter PulseClosing Technology Work?Figure 2 shows the current pulse generated by PulseClosing. This pulse is analyzed by IntelliRupter’s integrated Control Module using IntelliRupter’s unique PulseClosing Algorithm. The algorithm determines from the current pulse if the circuit is faulted. If a fault is detected the IntelliRupter remains open and resumes timing or goes to lockout. Otherwise IntelliRupter closes to restore service.

Using a Monte Carlo analysis the PulseClosing Algorithm was determined to be 99% accurate. The analysis included more than 40,000 cases, varying over 30 power system characteristics. Test parameters included substation transformer size, voltage, grounding, line segment length, overhead vs. underground, fault current, location, persistence, and load characteristics. The 1% where the algorithm cannot conclusively determine if a fault exists occurs when the fault currents coincide with high load currents. In these cases IntelliRupter will close with the energy let-through being very close to that of the load.

Easy Up Easy On!IntelliRupter has its own power source and inbuilt control and communication modules.

It does not need a separate 240V transformer, control box and lots of electrical spaghetti! Figure 3 shows an IntelliRupter with factory installed surge arrestors and an interlocked disconnect that provide a visual break for the linestaff working around the device.

After initial installation, the Modules for

11111111S&C’s IntelliTeam II ®

The Ultimate Self Healing Network

a secure network using spread spectrum frequency hopping technology developed for the US military and other security measures. It is used as an IP addressable device for communication between IED’s or to/from the SCADA control room. SpeedNet enables peer-to-peer communication between IED”s and also with the zone substation. From the zone substation, data is returned to the master station by RTU or fibre if available

SpeedNet’s high speed and low latency provide unmatched bandwidth in an unlicensed radio. SpeedNet also includes priority messaging to ensure critical data get through as fast as possible. The highest priority is for IntelliTEAM automation use; for decision making in times of crisis, this channel will be given priority. The other priority levels can be used for “smart metering” or AMI data allowing SpeedNet to can be used for the communication backbone supplying or backhauling information to/from smart meter networks.

Figure 3.IntelliRupter with integralinterlocked disconnects

Conventional reclosing in response to a permanent fault.

Pulseclosing in response to a permanent fault. The opposite-polarity pulse detects magnetizing inrush current; if the transformer is not faulted, IntelliRupter closes.

Figure 1.

Figure 2.

Figure 4: Powerco IntelliTEAM Stage 2: Bell Block

Figure 5: SpeedNet Radio Module

Figure 6: SpeedNet Pole Top Repeater Unit


Grafoplast®



Grafoplast

121212121212121212121212121212Ashburton 220kV UpgradeElectropar Adds Shearbolts to

Utility Market Offering

Electropar is pleased to announce that the Company has been appointed exclusive distributors for Shearbolt connectors manufactured by Nexans (GPH) of Germany. Competitively priced LV and MV shear bolt terminal and connectors for 16mm2 to 630mm2 Aluminium conductor and 10mm2 to 500mm2 Copper conductor will shortly be available from Electropar’s inventory in Auckland/Wellington and Christchurch.

All connectors and terminals stocked at Electropar are water blocked with a tinned surface finish.

The products stocked for both joints and terminals have the following range taking ability (note that the same connector can be used on Copper and Aluminium

Conductors)** Items designated can also be utilised

in 11kV and 22kV cable joints

Commercially, the benefit of a range taking shearbolt fitting is that a smaller number of stock items will provide a very wide range of coverage for LV / MV conductors.

Networks that have a mixture of old imperial and modern metric conductors within their underground cable network can be especially advantaged.

Application of Shearbolts DOES require Intelligence!

An important issue for Network Engineers to understand is that correct conductor compression must take place within shearbolt connector. The GPH shearbolt connectors and terminals are a Second Generation development of the technology.

The First Generation relied on a single torque shear. This was found to overcompress small conductors, yet leave large conductors largely un-compressed, within the specified range taking for a fitting.

The Second Generation technology introduces multiple torque shear for perfect installation on every conductor within the range of the connector. This is achieved by use of an advanced design of shear bolt that still uses standard tools.

Each fitting is packed with step by step instructions, providing the correct selection tool selection : an 6mm or 8mm Allen Key or a 13mm or 17mm socket, against the conductor size and type. Figure 1 demonstrates the multiple torque shear concept.

Shear Bolt Connectors - GPHThe Electropar Shearbolt Range of Links & Lugs Transpower Ashburton

GXP Re-Enforcement

New Zealand Transmission Network Service Provider (TNSP) Transpower New Zealand Ltd, together with AECOM and Transfield Services have executed a complex substation re-enforcement project at the important Ashburton Grid Exit Point (GXP). The project is a fast tracked brownfields initiative, completed in just 12 months. It has included a complex outage methodology, and close co-ordination between Transpower’s system planners, electricity generators, installation contractor and customers.

Prior to re-enforcement, the existing system configuration had one circuit of the double circuit CCH - TWZ 220kV line connected into Ashburton substation by an in-out loop. The loss of the 220 kV ASB-TIM-TWZ circuit is the worst n-1 contingency, as the load at Bromley and Ashburton substations must then be supplied from Islington substation by three remaining 220 kV circuits from the Waitaki Valley. The 220kV backbone that incorporates the Ashburton (ASB) site runs from

Ashburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV UpgradeAshburton 220kV Upgrade

Grafoplast®

Grafoplast®

Grafoplast

Flexible Bus Tubular Aluminium Busbar

Welded Busbar End Terminal

Sliding Busbar Support

Compression Terminals Midspan Bolted Busbar Splice

Bolted Run Tee Connector

Post Mounted Conductor Support

90o Busbar Support

Strung Bus

Busbar Welded Terminal

Conductor Earth Point

Shearbolt FittingsRange Taking Ability for Copper and

Aluminium ConductorsGPH Shearbolt

Joints and Terminal Lugs will suit Aluminium Conductors as

follows

GPH Shearbolt Joints and Terminal

Lugs will suit Copper

Conductors as follows

16 to 35mm2 10 to 25mm2

25 to 95mm2 25 to 95mm2

35 to 185mm2 25 to 150mm2

120 to 240mm2 120 to 185mm2

120 to 300mm2** 120 to 185mm2**

400 to 630mm2** 400 to 150mm2**

Figure 2: GPH Multiple Torque Shear Concept for 95mm2 – 240mm2 Copper

Terminal

Each connector is packed with coloured spacers which should be used with smaller conductors to ensure the conductor is concentric within the connector complete with pictorial selection instructions.

All individual sizes in the GPH product range have been tested under the International Standard IEC/EN 61238-1. Electropar will be pleased to provide copies of tests for all the GPH products upon request.

For more information, contact your local Electropar Sales Office

For more information, contact: [email protected]

Figure 1: Stock Standard Item 95-185mm2 Copper Shearbolt Terminal


Grafoplast®



Western Development Project NSW 500kV Substation Case StudyTransGrid 500kV

InvestmentDelivered by United Group Ltd

and Electropar

New South Wales Transmission Service Provider (TNSP) TransGrid has continued to invest heavily in development of its 500/330kV Substation Assets over 2007/2008/2009.

Early in 2007 United Group Infrastructure were awarded an important Design and Construct contract to build four large 500/330kV substations at the Bayswater, Mt Piper, Bannaby and Wollar sites.

This capital works project scope known as the “Western 500kV Development” is one of the largest ever seen in Australia, and is a combination of augmenting existing 330kV stations and construction of new Greenfield’s 500/330kV substation sites.

In turn, United Group Infrastructure awarded Electropar an initial contract for all of the 500/330kV tubular bus, strung bus and interplant equipment conductor

fittings for Bayswater and Mt Piper in June 2007. Identical primary scopes for Bannaby and Wollar were then awarded by United Group Infrastructure to Electropar in 2008.

Not only have these four projects been some of the largest ever completed by United Group Infrastructure and Electropar, they have also been some of the most technically complex. A large number of new components and assembly’s have been developed for the works and to substantiate their performance RIV testing at CSIRO in Sydney and electrical type testing to

IEC 61284 at Electropar’s independently accredited high current lab has been completed

Other components and assembly’s used at Bayswater, Mt Piper, Bannaby and Wollar have utilised Intellectual Property from TransGrid’s existing catalogue of 500kV components and assembly’s.

The combination approach to test new assembly’s and rely on TransGrid’s existing 500kV in service experience has been a successful one designed by United Group Infrastructure around engineering best practice for delivering EHV assets.

Electropar is delighted to have played a part in the development of these critical assets for the NSW transmission network alongside United Group Infrastructure.

Electropar CEO Grant Wallace comments that “Electropar has learned a great deal from the 500/330kV work completed in NSW with United Group Infrastructure for TransGrid, and the contract has lifted our

game in many facets of our business including design, testing and product traceability from source material.

The team is very proud to have been involved.

The Bayswater and Mt Piper sites are now energised with Bannaby well progressed in terms of construction and Wollar at 50% civil works stage. Both Bannaby and Wollar will be completed by United Group later in 2009.


131313131313131313131313131313131313131313131313Ashburton 220kV UpgradeTwizel (TWZ) to Timaru (TIM), then to Ashburton and finally to Islington (ISL) and Bromley (BRY) substations in Christchurch. The project removed this contingency by bussing the second ISL-TIM-TWZ circuit. In order to meet a Grid Reliability Standards requirement to allow for a failure of a bus coupler breaker, a third bus section was also required.

Augmenting the Ashburton site was a tricky proposition as the substation carries a heavy irrigation load for Canterbury’s dairy industry, with a summer peak. Due to operational constraints, the majority of outages were undertaken during weekend or holiday weekends over the 12 month period. Practically, the scope involved extending the switchyard to the west replacing 2 towers in the process, together with disconnection of all existing line circuits in combination with establishing new connections and maintaining

supply at all times. Post re-enforcement the site now has four 220kV line connections and is configured in an H Bus arrangement (compact) with staggered bus couplers.

A feature of the Ashburton project was the 3D CAD draughting of the site completed by Transpowers Design Service Provider AECOM. Luke Crowe at AECOM NZ Ltd started applying 3D CAD work in 1995 and now apply the 3D techniques to all T&D projects. Principal at AECOM’s Wellington office Don Wills comments that “3D is a highly productive and powerful tool, as it addresses the design principles of visualization, presentation, and verification. It ensures constructability, allowing the Suppliers, Contractors and Clients to see what’s proposed, and to contribute their ideas before sign-off. We

get very positive feedback from them!” Don also notes that “it also addresses Safety by Design, as it allows everyone to review the design from the different perspectives of Construction, Construction sequence, Maintenance and Operation”.

Electropar’s role in the Ashburton project was manufacture and supply of the tubular aluminium busbars and fittings together with fittings for all interplant connections. This included specially designed connections for the bus end connection of the pantograph disconnectors and a customised bipod arrangement to accommodate back to back feeder from an existing main bus. The system was supplied to site so that it simply bolted together without site welding. The 3D drawings supplied courtesy of AECOM and Transpower detailing the Ashburton site configuration have been overlaid with photos taken of the site where available, and with 3D images of Electropar fittings created by AECOM as part of the process.

For more information contact [email protected] or at AECOM Don Wills on [email protected]


allowing the Suppliers, Contractors and Clients to see what’s proposed, and to contribute their ideas before sign-off. We

drawings supplied courtesy of AECOM drawings supplied courtesy of AECOM drawings supplied courtesy of AECOM drawings supplied courtesy of AECOM and Transpower detailing the Ashburton and Transpower detailing the Ashburton and Transpower detailing the Ashburton and Transpower detailing the Ashburton site configuration have been overlaid with site configuration have been overlaid with site configuration have been overlaid with site configuration have been overlaid with photos taken of the site where available, photos taken of the site where available, photos taken of the site where available, photos taken of the site where available, and with 3D images of Electropar fittings and with 3D images of Electropar fittings and with 3D images of Electropar fittings and with 3D images of Electropar fittings created by AECOM as part of the created by AECOM as part of the created by AECOM as part of the created by AECOM as part of the process.

For more information contact For more information contact For more information contact [email protected] or at AECOM or at AECOM or at AECOM or at AECOM Don Wills on [email protected]@[email protected]@aecom.com

Tubular Aluminium Busbar

Fixed Busbar Support

Busbar Support & Compression Terminals



Tee Joint

Conductor Spacers

Busbar & Flexibiles

Substation Isometric Drawings By AECOM


Grafoplast®



Voltage Underhung Busbar System is being seriously considered for an upcoming greenfields 220kV site.

Some incredible footage of HV systems under incredible short circuit loads has been collected as a result of the testing.

This footage, and the strain data collected (1 Terabyte!) is currently undergoing detailed analysis. However, in addition to verifying the performance of the high voltage underhung busbar system, the testing has also verified the short circuit

performance of other Asset critical c o m p o n e n t s such as bus support posts, jumper/dropper connections and

rigid bus clamps and fittings.

The method of calculation for short circuit performance of these asset critical components is already the subject of a CIGRE working group as calculation methodologies have historically differed between and within designers and asset owners.The successful testing underscores the performance of Electropar’s substation

High Voltage Underhung Busbar System Phase To Phase Insulated

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in Vancouver, Canada (http://www.powertechlabs.com) in June 2009 after a global search for laboratory’s with capability to complete this challenging scope.

At Powertech Labs, Electropar built a full bay of 220kV (see main photo) utilising Transpower’s standard cage type concrete foundations, steel support structures, post

insulators and Electropar’s rigid bus/flexible conductor fittings so that the performance of all components of the system as would be installed in a real substation can be validated.

The Electropar/Transpower project team were responsible for the measurement of the loads and displacements of the system under varying fault conditions, and used a combination of high speed camera’s, still camera’s video and fibre optic sensors for data acquisition.

In all, 85 short circuit tests were completed over a 5 day test period between 25kA/0.3s and 63kA/1sec, including long duration tests at 40kA/3s. The system performed in accordance with expectation and as a result the High

systems and at the same time introduces a new concept in HV substation design and operation.

The new concept has been successfully tested, and has the potential to significantly lower capital cost of building substation assets. It also offers a substantial reduction in maintenance costs and improves access within the switchyard.

These outcomes are achieved with a minimal loss of operational flexibility and have the potential to result a step-change for substation primary construction in NZ and Australia.


NOVEL CONCEPT Andrew Renton TRANSPOWER INITIAL DESIGN Greg Barclay ELECTROPAR

QUARTER SCALE TEST ELECTROPAR Auckland Laboratory

FINAL DESIGN ELECTROPAR Engineering Department

HIGH POWER LABORATORY GLOBAL SEARCH ELECTROPAR Engineering Department

1414141414Electropar - Transmission Line Experts! Fulfilling Lines Company Needs For Over 50 Years!Electropar & Salvi Team

Creating a Powerful Transmission Line Package

Via a partnership with A. Salvi & Co or Milan, Italy, Electropar can now offer the same elegant end to end package for transmission and distribution line projects as for substations.

For some months Electropar and Salvi have been working closely together on some identifiable large projects that draw upon each organisations unique skills and competitive advantages. The Company’s are very complimentary, and the “fit” between what each operation brings to complex Transmission Line Projects has

proven to be a good one.

E l e c t r o p a r unders tands the demands of New Zealand and A u s t r a l i a n Transmission N e t w o r k S e r v i c e P r o v i d e r s (TNSP’s) and is very familiar

with the local performance requirements which are based largely on Australian Standard AS1154.

Salvi have incredible expertise at engineering customised transmission line solutions, and are arguably the world leaders in vibration control in terms of stockbridge dampers and spacer dampers technology.

Working in combination, and sharing information and partnerships in terms of global sources of supply for simple components creates a powerful commercial package to back the technical expertise.

For more information contact Cam Wallace at [email protected]

Electropar manufactures / designs or supplies the Transmission Line essentials!

• Compression Fittings • Implosive Fittings • Steel Forgings • Yoke Plates • Steel Hardware • Helical Suspension Units • Corona Rings • Armour Rods • Earthwire Assembly’s • OPGW Assembly’s • Spacer Dampers• Stockbridge Dampers• Polymer Longrod Insulators• Porcelain Disk Insulators• Glass Disk Insulators

AAC, ACSR, AAACAAC, ACSR, AAACHDG & compliant with Charpy Notch TestHDG for twin, tripe, Quad bundlesExtension Links, plate links, sag linksAAC, ACSR, AAACAluminium AlloyAluminium AlloySuspension and DeadendSuspension and Deadend

STRAIN TOWER FITTINGS

SUSPENSION TOWER FITTINGS


Grafoplast®



High Voltage Underhung Busbar System Phase To Phase InsulatedSHORT CIRCUIT TESTING

PROJECT

During 2008 and 2009 Electropar has been working closely with Transmission Network Service Provider (TNSP) Transpower NZ Ltd, on a ground breaking substation project. Together, the two Company’s have embarked upon a programme to mathematically validate and then short circuit test a full size bay width of phase to phase insulated 220kV 200mm OD (4000amp) busbar and interplant connections at 25kA, 31.5kA and 40kA/3s fault levels.

On the strength of a convincing commercial argument, Transpower and Electropar desired to prove that phase to phase insulation in transmission substations is not just technically possible; it is the future of design for delivering the best value

Transmission Assets.

The commercial argument was based on the reduction in quantity of foundations/civil works in addition to shrinking the footprint of the air insulated switchyard. Financial analysis indicated that the cost saving in civil works, electrical equipment and real estate was substantial enough to warrant the investment in a development programme.

Before practical test could be considered though, the first milestone was to have the fundamental design elements examined and ratified by an independent and suitably qualified consultant.

The analysis centered around the mechanical withstand of the system and was completed by Beca Carter

(Auckland) in the third quarter of 2008. The Beca work was then peer reviewed by Maunsell prior to Christmas 2008.

Subsequently all parties agreed that the mathematical calculations indicated the system would withstand the short circuit forces generated under Transpower’s worst case fault scenario. However, to provide an additional level of confidence a finite element analysis (FEA) was completed to further verify critical load points within the system.

As a result of gaining agreement that technically the High Voltage Underhung Busbar System was feasible, Stage 2 of the project has been completed. Practical short circuit testing of the busbar system.

The testing took place at Powertech Lab’s

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1515151515New Product Releases

sampling plan.

This work is done with our own set of calibrated Go/No Go gauges, shown in the picture adjacent. The Go/No Go gauges have been calibrated with a (cmm) post manufacture, and certified as dimensionally correct to within 1000th of a millimetre.

When Electropar delivers ball and socket fittings, we don’t just say “they are correct”, we can prove it! For more information

Ever looked at a transmission or a distribution or line hardware forged or cast fitting ball or socket and thought “how do I tell if this is exactly what it should be and it is OK?!”

For some items, it is a simple matter of measurement to prove that the fitting is dimensionally acceptable. For example for a 160kN clevis, it is a case of measuring the width of the clevis and the diameter of the pin.

The fit between ball and socket fittings is equally as critical and clevis and tongue but impossible to measure on site other than by fitting the two items together for a quick physical check. However, this type of inspection will prove only that the items don’t mechanically foul one another: it won’t prove compliance with the standard that defines the size and shape of the IEC16mm and 20mm ball and socket fittings. Enter Ball and Socket Go/No Go gauges!

The principle of Go/No Go gauges is simple. If a “Go” gauge fits the item being measured, it’s OK. If a “No Go” gauge fits the item being measured, something is amiss! At Electropar, to ensure that all ex production ball and socket fittings are dimensioned in accordance with relevant standards we sample test each batch of ball and socket forgings in accordance with a

Ball & Socket GaugesScience behind Transmission Forgings Q.A.

Helical Suspension UnitsElectropar Introduces New Range

angles up to 300 and twin configuration for greater angles, the Electropar Helical Suspension Units are tested in accordance with the requirements of AS1154.

For more information contact your local Electropar office or

[email protected]

To enhance it’s competitiveness for distribution and transmission line project packages, Electropar has introduced it’s own range of Helical Suspension Units for AAC, ACSR and AAAC conductors from 13mm to 35mm.

Utilising industry standard aluminium alloy armour rods and a cast conductor clamp, the rubber insert is manufactured from ozone resistant EPDM rubber.

Available in single configuration for

sampling plan.

contact [email protected]

Substation Primary System Innovation Electropar High Voltage Underhung Busbar System Test Rig

Powerlabs, Vancouver, Canada 2009


New Zealand: Freephone: 0800 733 735 Freefax: 0800 733 736Australia: Freephone: 1800 141 502 Freefax: 1800 141 503 www.electropar.co.nz email: [email protected] November - Issue 9.2

1616161616Power Distribution Equipment The Electropar Team have you Covered!



Cover Image. Substation Primary System Innovation Electropar High Voltage Underhung Busbar System Test Rig Powerlabs, Vancouver, Canada 2009

Electropar’s claim to be expert in the Power Distribution equipment arena is backed by some serious experience : the Company has been in the power line since the 1960’s!. Thanks to successful long-standing partnerships with best in class international suppliers, together with best practice R&D and manufacturing for underground and overhead distribution line and station equipment, the Electropar package is a powerful one.

Whether it’s connectors, surge protection, insulators, G&B gear, linemans tools or Arc Flash protection, the Electropar team have you covered!


Powerline Binder Nov1

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Transcript of Powerline Binder Nov1