POWERFORMED® Substations Catalogue: Section 1 General Information General Section 1 - General Information Table of Contents Sec/Page Introduction to POWERFORMED®........................................................................... 1-4 Pictorial Index.......................................................................................................... 1-5 User Guide.............................................................................................................. 1-9 Australian Standard Terminal Palms......................................................................... 1-10 Standard Primary Equipment Stud Sizes................................................................. 1-11 Nominal Dimensions And Weights........................................................................... 1-12 Current Ratings By Temperature.............................................................................. 1-14 Short Circuit Ratings................................................................................................ 1-15 Thermal Expansion ................................................................................................. 1-16 Deflection Values..................................................................................................... 1-17 Standards................................................................................................................. 1-19 Busbar Tube Aluminium Alloys................................................................................. 1-20 Deflection & Stress Formulae................................................................................... 1-22 Aluminium Casting Alloys......................................................................................... 1-23 Damping Conductors............................................................................................... 1-24 Expansion Supports and Connectors....................................................................... 1-25 Principals of Electrical Jointing................................................................................. 1-26 Metric Fastenings..................................................................................................... 1-28 Bolted Aluminium Joints........................................................................................... 1-29 Non Tension Compression Fittings........................................................................... 1-30 Welding.................................................................................................................... 1-32 1 - 3 Introduction to POWERFORMED® BUSLIGN™ for Busbars, SUBLIGN™ for Flexible Conductors Preformed Line Products (PLP) Preformed Line Products (PLP) is a worldwide designer, manufacturer and supplier of high quality products for the electric power Distribution and Transmission industries. With an equally strong presence in the Communications and Solar industry segments, PLP is a global power and fibre infrastructure specialist. Located in 16 countries around the world, PLP’s flexibility and global presence allows it to respond to customer’s needs quickly and with precision. With ground breaking and innovative solutions like THERMOLIGN® products for high temperature transmission lines and COYOTE® Fibre Optic Products PLP have consistently pioneered advances in power utility communications and communications networks since 1947. PLP was founded on technology for supporting, protecting, terminating and splicing transmission and distribution lines, OPGW (Optical Ground Wire) and ADSS (All Dielectric Self Supporting) fibre optic cables. The Company’s reputation, product reliability and longevity speaks for itself. You can count on PLP’s energy products and people day in and day out, year after year. That is because a steadfast commitment to quality is not just a goal at PLP, it’s an obsession. In our engineering laboratories, on the manufacturing lines and all the way to field installation, it’s the guiding principle of everything we do. POWERFORMED® Substation Systems Preformed Line Products POWERFORMED® Substation systems are a product of the company’s global engineering design, testing and manufacturing strengths. Proven over many years of reliable in-service performance at voltages up to 500kV, the intellectual property and designs that underpin POWERFORMED® fittings are drawn from as far afield as Australia, New Zealand, Poland, South Africa, and Thailand. Within the POWERFORMED® range are two distinct families of connectors, clamps and hardware for substation products. The families are called BUSLIGN™ and SUBLIGN™. Within these families, the fittings have been divided into three distinct groups which are structured around application voltages within substations: 1. Fittings that are designed to be applied at voltages up to and including 230kV 2. Fittings that are designed to be applied at voltages between 245kV and 400kV 3. Fittings that are designed to be applied at voltages between 400kV and 500kV BUSLIGN™: Substation Fittings for Tubular Aluminium Busbars POWERFORMED® BUSLIGN™ aluminium substation fittings includes both bolted, and welded solutions. Designed to be used to create high current tubular aluminium busbar systems in high voltage AC and DC substations, BUSLIGN™ fittings are available to suit both SPS (Standard Pipe Size) and Metric aluminium busbar tubes as large as 8 inch and 250mm OD (Outside Diameter). Conservatively designed for long and reliable in-service life, PLP’s BUSLIGN™ range represents some of the latest thinking in power engineering product design, backed by mechanical, heat cycle, Corona and RIV short circuit testing at up to 63kA/1s. SUBLIGN™: Substation Fittings for Flexible Aluminium Conductors POWERFORMED® SUBLIGN™ flexible conductor fittings encompasses bolted, welded and compression fitting solutions for AAC, AAAC, ACSR and ACAR flexible aluminium conductors. With some of the most unique and flexible designs available, installation is fast, easy and most importantly reliable for critical substation assets. Backed by extensive testing to NEMA, ANSI and IEC standards, SUBLIGN™ connectors are the low risk choice for substation assets. 1 - 4 POWERFORMED® Substations Catalogue: Section Pictorial Index 1 General Information General PALMS/FLAGS FLEXIBLE CONNECTORS SUPPORTS AAP AFC BRPI Aluminium Aluminium Bolted Run Post Adaptor Plates Flexible Insulator Connectors 2-8 3-2 BBAP D-FL D-ABS Busbar Copper Flexible Aluminium Aluminium Palm Connectors Busbar (Inline) Support Clamp (Type ABS) 3-26 2-10 2-16 BBAPT Busbar D-BS Aluminium Palm Copper Busbar (Transverse) Support Clamp END CAPS (Type BS) 2-4 BBEC 2-16 BBECP Busbar End Caps DCRIP Busbar End Cap Double Conductor Palm Run Insulator Post 2-2 2-4 3-2 BBEP D-PTC Busbar End Palm Tube Connector (Capped) Type PTC Copper JOINT SLEEVES 2-5 BBJS 2-17 Busbar Joint BBEPL Sleeves D-TF Busbar End Palm Tube Connector (L-Type) Type TF 2-7 Copper & ATF Aluminium 2-15 2-17 SPSD Parallel Spacer Double Post Insulator Mounted A FRAMES SUPPORTS 3-3 BBAFA BBFCS Busbar A-Frames Busbar Fixed SPSQ Aluminium Conductor Parallel Spacer Support Quad Post Insulator Mounted 2-6 3-2 3-3 BBSA Busbar Support SPST Assembly Parallel Spacer Triple Post Insulator Mounted 2-14 3-3 1 - 5 Pictorial Index BOLTED CONNECTIONS BOLTED CONNECTIONS BOLTED CONNECTIONS APG D-AST D-NT Aluminium Aluminium Terminal Lug Parallel Straight Connector Conductor Groove (Clamp) Busbar to Busbar to Palm Type NT Copper 3-14 2-19 3-23 BBTL D-AT D-PC Busbar Aluminium Tee Palmless Connector Terminal Lug Connector PC/PCS Copper Busbar to Conductor & APC/APCS (Type AT) Aluminium 2-26 3-20 3-4 BRBS D-ATC D-RS Bolted Run Aluminium Tee Reducer Bolted Stem Connector Busbar or Studs Cond. to Cond. Type RS - Copper (Type ATC) 3-16 3-22 2-20 BRBT D-ATT D-RT Bolted Run Aluminium Tee Reducer Busbars Bolted Tee Connector Type RT - Copper Busbar to Busbar (Type ATT) 3-15 2-21 2-20 BRCT D-BT D-SC Bolted Run Terminal Lug Straight Connector Compression Tee Busbar to Palm Conductor (Type BT - Copper) to Conductor Type SC Copper 3-15 2-24 3-21 BRPT D-CS D-ST Bolted Run Terminal Lug Stud Copper Straight Palm Tap or Busbar to Palm Connector (Type CS Copper) Busbar to Busbar 3-14 2-25 2-19 BRTL DCRBS D-T Bolted Run Double Conductor Tee Connector Terminal Lug Run Busbar to Bolted Stem Conductor Type TT Copper 3-16 3-17 3-18 D-ABT DCRBT D-E Aluminium Double Conductor End Connector Terminal Lug Run Busbar to Busbar to Palm Bolted Tee Conductor Type E Copper 2-23 3-17 D-AE DCRPT D-TC Aluminium End Double Conductor Tee Connector Connector Run Conductor to Busbar to Conductor Palm Tap Conductor (Type AE) Type TC Copper 3-21 3-16 3-22 D-AN D-LS D-TT Aluminium Terminal Right Angle Tee Connector Lug Conductor to Aluminium Busbar to Palm (Types AN & Terminal Lug Busbar AN-B22) Busbar to Palm Type TT Copper 3-23 2-25 2-22 1 - 6 POWERFORMED® Substations Catalogue: Section Pictorial Index 1 General Information General PROTECTION, EARTHING & BOLTED CONNECTIONS CONDUCTOR TERMINATION ACCESSORIES D-TL CDEA ALMINOX Terminal Lug Compression ALV300 Conductor to Deadend (AAC) Electrical Jointing Palm Type TL Compound Copper & ATL Aluminium 3-11 4-18 3-23 CDEAAAC BBES D-TL Compression Busbar Earthing Right Angle Dead-end Stirrup Terminal Lug (AAAC) Conductor to Palm Type TLC 3-12 2-3 Copper & ATLC Aluminium CTA/CDET BBESA 3-24 Aluminium Comp. Busbar Earthing Terminals Stirrup Comp. Deadend Assembly Terminal 3-9 3-5 CTAPTW CBL Spacers Compression Copper Bonding Terminal Leads