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(4)-G77700-S0019-L058-A
Description:
400 kV SWITCHYARD
DESIGN
REPORT’s & CALCULATION’s
Subject:
Note:
This report establishes the sizing of conductors on the basis of thermal
calculation for 400 kV Switchyard at Gilgel Gibe II Hydroelectric Project,
Ethiopia.
Conductor Selection Design Report : Thermal Calculation Page: 3 of 7
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Contents
page
1. Introduction ....................................................................................................................... 4
2. System Data...................................................................................................................... 4
5. Attachments ...................................................................................................................... 6
6. Conclusion ........................................................................................................................ 6
7. References........................................................................................................................ 7
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1 Introduction
The thermal calculation for conductors may be broadly divided into two categories:
The current carrying capacity of a conductor is the maximum steady-state current inducing a
given temperature rise in the conductor, for given ambient conditions. The continuous current
carrying capacity depends on the type of conductor, its electrical resistance, the maximum
allowable temperature rise and ambient conditions. The conductor ampacity is limited by the
conductor’s maximum operating temperature. The temperature of a conductor depends upon
the balance of heat input and output. The conductor in an outdoor switchyard gains heat
mainly from solar radiation incident on it and the heat generated by Joule effect. Conductor
looses heat by radiation and convection from its surface. This relationship is expressed in the
Heat balance Equation which in turn gives the value of allowable magnitude of current
through the conductor (for details refer detail calculation).
A conductor’s temperature will rise rapidly under fault conditions. This is due to the inability of
the conductor to dissipate the heat as rapidly as it is generated. The magnitude and duration
of short circuit fault current that can be sustained by the conductor depends upon the
electrical conductivity and area of cross-section of the conductor withstanding the fault
current. This fault current withstanding capacity is limited to the maximum allowable
temperature rise of the conductor based on its material properties beyond which the
conductors become vulnerable to annealing. In the present calculation, the conductor area
necessary for withstanding the fault current for the given time duration is determined
considering final conductor temperature limited to 2000 C.
2 System data
400kV AC Switchyard
System Frequency 50 Hz
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B. Rigid Conductor
Wall thickness 6 mm
Wall thickness 8 mm
Wall thickness 6 mm
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1. Solar radiation absorption coefficient 0.5 (as per Cl. No. 3.10 of
IEC 1597 : 1995)
2. Intensity of solar radiation at site 900 W/m2 (as per Cl. No.
3.10 of IEC 1597 : 1995)
3. Emissivity coefficient of conductor with respect black body 0.6 (as per Cl. No. 3.10 of
IEC 1597 : 1995)
5 Attachments
Attachment-1: Calculations of Continuous Current Carrying capacity for 954 MCM Cardinal
Conductor.
Attachment-2: Check for Short Circuit Current Withstanding Capacity of ACSR Conductor
Attachment-6: Check for Short Circuit Current Withstanding Capacity of Al. Tubes
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permitted without express written authority. Offenders will be liable for
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of a utility model or design, are reserved.
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6 Conclusion
1. Flexible Conductor: From the calculation it is inferred that Twin 954 MCM ACSR with a derated
continuous current carrying capacity of 2287 Amps is suitable for all types of connections with
flexible conductors i.e. conductors incoming and outgoing to the switchyard at the Transformer &
OHL Feeders, equipment connection droppers, jumpers etc and the Jack Bus at the Coupling
Feeder along with the droppers & jumpers associated to it. The conductor is capable of with-
standing fault current upto 31.5 kA for 1 sec duration in the configuration mentioned above.
2. Rigid Conductor: From the calculation it is inferred that the all of the selected tubes can carry
more than 2000 Amps of current continuously at 80 0C temperature and can withstand fault cur-
rent of 31.5 kA for 1 sec. Thus the selection of tubes for switchyard design may now entirely be
attributed to their mechanical properties for various spans of installation. With a conservative
consideration of current carrying capacity the following selection is adopted in further
engineering:
x 120/8 mm AlMgSi0.5F25 Tubular Bus bar to serve as Equipment Bus Conductor at the
Bus Coupling feeder.
x 120/6 mm AlMgSi0.5F25 Tubular Bus bar to serve as Equipment Bus Conductor at the
Transformer & Line feeders.
7 References
1. IEC 1597 :1995 Overhead electrical conductors – Calculation methods for stranded bare
conductors.
2. IEEE Std 605 : 1987 IEEE Guide for Design of Substation Rigid-Bus Structures.
3. Technical Data sheet for 954 MCM Cardinal Conductor: Manufacturer – HASCELIK
4. Technical Data sheet for Aluminum Alloy Tubular Conductor: Manufacturer – Corus.
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permitted without express written authority. Offenders will be liable for
damages. All rights, including rights created by patent grant or registration
of a utility model or design, are reserved.
(4)-G77700-S0019-L058-A
S (4)-G77700-S0019-L058-A
Attachment - 1
where,
Pj is the heat generated by Joule effect
Psol is the solar heat gain by the conductor surface
Prad is the heat loss by radiation of the conductor
Pconv is the convection heat loss
where,
RT is the electrical resistance of conductor at a temperature T (:/m)
I is the conductor current (A)
The value of RT2 will be substituted in equation 2 and value of I will be found. Refer Equation 8 below.
where,
J is the solar radiation absorption coefficient = 0.5
D is the conductor diameter = 0.03042 m
2
S i is the intensity of solar radiation = 900.00 W/m
where,
s is the Stefan-Boltzmann constant = 5.67E-08 W.m -2.K-4
D is the conductor diameter = 0.03042 m
K e is the emissivity coefficient in respect to black body = 0.6
T 1 is the ambient temperature = 35oC = 308 K
T 2 is the final equilibrium temperature = 80oC = 353 K
Nu is the Nusselt number and is given by the equation : Nu = 0.65Re0.2 + 0.23Re0.61 ……(6)
where,
O is the thermal conductivity of the air film = 0.02585 W.m -1.K-1
in contact with the conductor
T 1 is the ambient temperature = 35oC = 308 K
T 2 is the final equilibrium temperature = 80oC = 353 K
v is the wind speed (minimum) = 1 m/s
D is the conductor diameter = 0.03042 m
=> Re = 1640.347
=> Nu = 23.887
Where,
Prad = 21.22 W
Pconv = 87.29 W
Psol = 13.69 W
RT2 = 7.2500E-05 :/m
Therefore,
954 MCM Twin Cardinal conductor is capable of carrying a continuous current # 2287 A
Attachment - 2
Reference Document : CBIP paper on 'Overload and Fault Current limitations of Aluminium Conductor'
Maximum Fault Current that can be allowed to flow through the conductor with it's final temperature within
the limits determined by it's mechanical properties is given by :-
Therefore, for a system with given fault level, the cross-sectional area of the conductor suited to withstand the fault
current for the defined duration and within the allowable final temperature is determined from the equatioin above as :-
………………(2)
Now, for the given system the values are :-
I = 31500 A
n = 1
C = 0.2469 g-cal/0C
G = 2.703 g/cm3
D
0
= 0.00403 / C
U = 2.617E-06 :-cm2/cm
t = 1 sec
0
Tf = 200 C
0
Ti = 80 C
Therefore, required Cross-sectional Area of the conductor suited to withstand the fault current for the defined duration and
within the allowable final temperature of the conductor
2
A = 337.42 mm
At < A
Hence, actual cross-sectional area of the conductor, At (547.34 mm2) is more than the required cross-sectional area
A( 337.42mm2). Thus selected conductor is capable of withstanding the Short Circuit Fault Current safely
Attachment - 3
Design Inputs :
a. Outer Diameter of tube = 250 mm
b. Wall Thickness = 6 mm
c. Cross-sectional area = 4600 mm2
d. Electrical conductivity = 28 m/:mm
e. Design Ambient Temperature Ta = 35 0
C
f. Maximum Operating Temperature Tf = 80 0
C
g. Temperature coefficient of resistance D = 0.000125 :mm.
where,
I
Pj is the heat generated by Joule effect
Psol is the solar heat gain by the conductor surface
Prad is the heat loss by radiation of the conductor
Pconv is the convection heat loss
2
2. The power loss, I RF, due to Joule effect is given by : Pj = I2RF ……(2)
Electrical Resistivity of tube at 200 C U = 3.5714E-02 :mm /m
Now, Resistance at 200 C per unit length R20 = U / A :/m
= 7.7640E-06 :/m
Resistance at max. operating temperature Rf = R20[1 + D(Tf-20)]
R80 = 7.8222E-06 :/m
= 2.3841E-06 :/ft
The ratio Rac/Rdc is a measure of the skin effect. For a conductor of given shape, the first step is to calculate : (f/R dc x
1000)^0.5, and then to find the ratio Rac/Rdc for this value from the corresponding t/d curve
where,
[' is the solar radiation absorption coefficient = 0.5
I= effective angle of incidenceof Sun =
= 90 deg
cos-1*[cosHc*cos(Zc-Z1)] (As per
considering Hc = 87 deg Table-1,
Zc = 0 deg Pg-42,43 :
Z1 = 90 deg IEEE 605)
2
Q s is the intensity of solar radiation = 78.90 W/ft
2
A' is projected area of conductor,Squaer inches per foot = = 118.20 in /ft
12*sin] * conductor size
K = Heat multiplying factors for high altitudes = 1.15 (Table-1, Pg-46) IEEE 605
where,
2
A is the conductor surface area = 371.34 in /ft
H is the emissivity coefficient in respect to black body = 0.5
T a is the temperature of = 308 K
35 oC
surrounding bodies in kelvin
T c is the maximum operating 80 oC = 353 K
temperature of conductor
Where,
qr = 44.73 W/ft
qc = 66.93 W/ft
qs = 37.27 W/ft
R65F = 2.4318E-06 :/ft
Attachment - 4
Design Inputs :
a. Outer Diameter of tube = 120 mm
b. Wall Thickness = 8 mm
c. Cross-sectional area = 2820 mm2
d. Electrical conductivity = 28 m/:mm
e. Design Ambient Temperature Ta = 35 0
C
f. Maximum Operating Temperature Tf = 80 0
C
g. Temperature coefficient of resistance D = 0.000125 :mm.
where,
I
Pj is the heat generated by Joule effect
Psol is the solar heat gain by the conductor surface
Prad is the heat loss by radiation of the conductor
Pconv is the convection heat loss
2
2. The power loss, I RF, due to Joule effect is given by : Pj = I2RF ……(2)
Electrical Resistivity of tube at 200 C U = 3.5714E-02 :mm /m
Now, Resistance at 200 C per unit length R20 = U / A :/m
= 1.2665E-05 :/m
Resistance at max. operating temperature Rf = R20[1 + D(Tf-20)]
R80 = 1.2760E-05 :/m
= 3.8889E-06 :/ft
The ratio Rac/Rdc is a measure of the skin effect. For a conductor of given shape, the first step is to calculate : (f/R dc x
1000)^0.5, and then to find the ratio Rac/Rdc for this value from the corresponding t/d curve
where,
[' is the solar radiation absorption coefficient = 0.5
I= effective angle of incidenceof Sun =
= 90 deg
cos-1*[cosHc*cos(Zc-Z1)] (As per
considering Hc = 87 deg Table-1,
Zc = 0 deg Pg-42,43 :
Z1 = 90 deg IEEE 605)
2
Q s is the intensity of solar radiation = 78.90 W/ft
2
A' is projected area of conductor,Squaer inches per foot = = 56.74 in /ft
12*sin] * conductor size
K = Heat multiplying factors for high altitudes = 1.15 (Table-1, Pg-46) IEEE 605
where,
2
A is the conductor surface area = 178.24 in /ft
H is the emissivity coefficient in respect to black body = 0.5
T a is the temperature of = 308 K
35 oC
surrounding bodies in kelvin
T c is the maximum operating 80 oC = 353 K
temperature of conductor
Where,
qr = 21.47 W/ft
qc = 43.09 W/ft
qs = 17.89 W/ft
R65F = 3.9667E-06 :/ft
Attachment - 5
Design Inputs :
a. Outer Diameter of tube = 120 mm
b. Wall Thickness = 6 mm
c. Cross-sectional area = 2150 mm2
d. Electrical conductivity = 28 m/:mm
e. Design Ambient Temperature Ta = 35 0
C
f. Maximum Operating Temperature Tf = 80 0
C
g. Temperature coefficient of resistance D = 0.000125 :mm.
where,
I
Pj is the heat generated by Joule effect
Psol is the solar heat gain by the conductor surface
Prad is the heat loss by radiation of the conductor
Pconv is the convection heat loss
2
2. The power loss, I RF, due to Joule effect is given by : Pj = I2RF ……(2)
Electrical Resistivity of tube at 200 C U = 3.5714E-02 :mm /m
Now, Resistance at 200 C per unit length R20 = U / A :/m
= 1.6611E-05 :/m
Resistance at max. operating temperature Rf = R20[1 + D(Tf-20)]
R80 = 1.6736E-05 :/m
= 5.1008E-06 :/ft
The ratio Rac/Rdc is a measure of the skin effect. For a conductor of given shape, the first step is to calculate : (f/R dc x
1000)^0.5, and then to find the ratio Rac/Rdc for this value from the corresponding t/d curve
where,
[' is the solar radiation absorption coefficient = 0.5
I= effective angle of incidenceof Sun =
= 90 deg
cos-1*[cosHc*cos(Zc-Z1)] (As per
considering Hc = 87 deg Table-1,
Zc = 0 deg Pg-42,43 :
Z1 = 90 deg IEEE 605)
2
Q s is the intensity of solar radiation = 78.90 W/ft
2
A' is projected area of conductor,Squaer inches per foot = = 56.74 in /ft
12*sin] * conductor size
K = Heat multiplying factors for high altitudes = 1.15 (Table-1, Pg-46) IEEE 605
where,
2
A is the conductor surface area = 178.24 in /ft
H is the emissivity coefficient in respect to black body = 0.5
T a is the temperature of = 308 K
35 oC
surrounding bodies in kelvin
T c is the maximum operating 80 oC = 353 K
temperature of conductor
Where,
qr = 21.47 W/ft
qc = 43.09 W/ft
qs = 17.89 W/ft
R65F = 5.2029E-06 :/ft
Attachment - 6
Maximum Fault Current that can be allowed to flow through the tubular conductor with it's final temperature within
the limits determined by it's mechanical properties is given by :-
Therefore, for a system with given fault level, the cross-sectional area of the conductor suited to withstand the fault
current for the defined duration and within the allowable final temperature is determined from the equatioin above as :-
7.76398E-06 :/m
0
Conductor Resistance at 20 C = (from ampacity calculation)
= 2.36634E-06 :/ft
Now, as per IEEE 605, the resistance of aluminium alloys at a temperature is is expressed as :
RT2 = (8.145*10^-4/C'A2)*(1+0.00403*C'*(T2-20)/61) ………………(2)
where C' = Conductivity of Al. alloy in % IACS
2
A2 = Cross-sectional area of conductor in in
2
= 7.13 in
0
Hence deriving from eqn ..(2) for 20 C temperature, the value of C' is calculated as :
C' = 48.28 % IACS
Therefore, required Cross-sectional Area of the conductor suited to withstand the fault current for the defined duration and
within the allowable final temperature of the conductor
2
A = 405.85 mm
At < A
Hence, actual cross-sectional area of the tube, At (4600 mm2) is more than the required cross-sectional area
A( 405.85mm2) Thus selected Al. Tube is capable of withstanding the Short Circuit Fault Current safely
The cross-section area of 120/8 mm and 120/6 mm Tubular busbars are 2820 mm2 & 2150 mm2 respectively which
is also sufficiently larger than the area required to carry the maximum fault current. Thus it may be concluded
that the selected tubes are capable of withstanding the Short Circuit fault Current safely.