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Taikai Cable

Manufacturing Expert of

Compound Insulated Shiedling Copper Tubular Busbar

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Taikai Cable located in Tai’an city with the famous mountain Tai Mountain.

Taikai Appearance View

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Contents

Summary ........................................................................................................................................................................... 4

Features ............................................................................................................................................................................ 5

Structure and description ................................................................................................................................................. 5

The condition the Compound Insulated Shiedling Copper Tubular Busbar been used .................................................... 6

Technical Parameters ........................................................................................................................................................ 8

Classic solution ................................................................................................................................................................ 15

Product comparison ........................................................................................................................................................ 20

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Compound Insulated Shiedling Copper Tubular Busbar

Summary

When the generator and power substation come to a new generation, traditional open rectangle bus bar can not meet the

demand of irregular distribution load, large coefficient of skin effect, severe thermal dissipation problem, dynamic thermal

stability and current carrying capability, that it can not meet the capacity of increasing power transmission. We have

invented triple-extrusion composite shielded insulated bus bar, inspired by triple-extrusion XLPE insulated power cable.

The current carrying media of bus bar is hollow tubular conductor, with triple-extrusion technology outside of the tubular.

The three layers of polymer material extruded are called internal shield, insulation, outside shield, which make the tubular

conductor complete insulated. The composite shield insulated bus bar is one kind of new generation. There are several

advantages compare to the traditional bus bar, such as carrying larger current, low skin effect, little efficiency loss, lower

temperature rising, better thermal dissipation and insulation performance, and smaller space occupied etc.

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Features

1. Big current loading, higher mechanical strength, large allowable contract stress.

2. Small coefficient of skin effect, Kf≦1, low AC resistance, and the power loss is about 1/4 of rectangle bus bar with the

same cross section area.

3. Good thermal dissipation, low temperature rise, long service time.

4. Insulation material, with excellent anti-aging performance, weather resistance, and stable electric and mechanical

performance, are imported EPDM, to ensure the life time longer than 30 years.

5. Safety have been improved, for perfect insulation performance, little distance between every phase and to the the

earth, economizing the land resources, reducing the opportunity of shortage caused by human beings and animal

contact.

6. Simple structure, easy to install, low cost of construction, and there is barely maintenance.

Structure and description

a. Composite shielded insulated bus bar contains tubular conductor, conductor shielded layer, insulation layer, insulation

shielded layer, metallic shielded layer and out sheath.

1

2

3

4

5

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1. Tubular conductor

2. Conductor shielded layer

3. Insulation layer

4. Insulation shield layer

5. Metallic shield layer

6. Sheath

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b. Description

TK

G G M

1

2

3

4

5

6

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1. Rated current (A)

2. Rated voltage U(KV)

3. Out sheath

J: Metallic

Y: PE

4. Conductor

T: Copper

L: Aluminum

5. Insulation

H: Epoxy resin

E: EPR

G: Silicone rubber

6. Dry insulated tubular bus bar

7. Company name code

The condition the Compound Insulated Shiedling Copper Tubular

Busbar been used

1. Regular condition

A. Apply to condition such as indoors, outdoors, tunnel, Trench and interlayer etc.

B. Ambient air temperature ranging from -40 ℃ to +40℃.

C. Altitude height not more than 1000m

D. Relative humidity: daily average value not more than 98%, monthly average no more than 95%

E. Seismic fortification intensity (basic seismic acceleration 0.3g)

F. Wind pressure no more than 700Pa (about 34m/s)

G. Sunlight intensity 0.1w/cm2

H. Icing thickness no more than 20mm

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2. Special service conditions

A. As for the composite insulated shielded bus bar, the ambient temperature, higher than 40℃, the test voltage of

insulated in dry ambient, and withstand voltage times KT(temperature correction coefficient)

KT=1+0.0033(T-40)

Note of formula: T—the temperature in the ambient air.

B. As for the altitude between 1000m and 4000m, the dielectric withstand voltage of composite shielded insulated bus

bar should be corrected according to GB3.11.1-2012 standard.

C. When necessary, composite shielded insulated bus bar besides terminal, can be used in corrosive gas, conductive and

explosive dusts. The designing and application are cooperated by supplier and demander, when special operating

condition.

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Technical Parameters

1. Rated voltage

Rated voltage of composite shielded insulated bus bar show as follows, standard GB/T 156-2007

Form5-1 Composite shielded insulated bus bar

Form 5-1

Nominal voltage of system (U) Rated voltage U0 Maximum voltage of system Um

1 0.6 1.2

3 1.8 3.6

6 3.6 7.2

10 6 12

15 8.7 18

20 12 24

35 26 40.5

2. Rated current

The rated current of composite shielded insulated bus bar is 630, 800, 1000, 1250, 1600, 2000, 2500, 3150, 6300,

8000, 10000A according to GB/T 762-2002.

3. Rated frequency

Rated frequency of composite shielded insulated bus bar is 50Hz.

4. Insulation level

The insulation level of composite shielded insulated bus bar shows as following chart 5-2, as per GB311.1-2012.

Chart 5-2

Nominal

system

voltage U

Maximum

system

voltage Um

Insulation level

Power frequency withstand voltage within 1 minute Rated impulse lightning

withstand voltage(Peak) Wet (effective value) Dry (effective value)

1 1.2 6 6 ---

3 3.6 18 25 40

6 7.2 23 30 60

10 12 30 42 75

15 17.5 40 55 95

20 24 50 65 125

35 40.5 80 95 200

5. Dynamic thermal stability of composite shielded insulated bus bar

According to the requirement of GB/T11022-2009 and GB/T 762-2002, the current list for dynamic thermal stability of

composite shielded insulated bus bar, showed in Chart 5-3.

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Chart 5-3 The current list for dynamic thermal stability of Compound Insulated Shielding Copper Tubular Busbar, Current

Rated current(effective

value: A)

Current of thermal stability(4S) (effective

value: kA)

Current of Dynamic stability (Peak

value: kA)

630~10000

16 40

25 63

31.5 80

40 100

50 125

63 160

80 200

80 200

6. Permissible temperature and rise of Compound Insulated Shielding Copper Tubular Busbar

According to the requirement of GB/T 11022-2009, the permissible temperature and rise of composite shielded insulated

bus bar meet the requirement in Chart 5-4

Chart 5-4 Permissible temperature and rise.

Insulation material Permissible Max. temperature of Conductor Permissible Max. temperature

rise of Conductor (K) Long running Short circuit

Epoxy resin

90 250 50 Silicone rubber

EPR

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1kV Compound Insulated Shielding Copper Tubular Busbar

Rated

current

Frequency

withstand voltage

for 1min

Thermal stable

current(4S)

Dynamic

stable current

Bending

radius

Temperature

rise

Phase

space Busbar span

1600A 6kV 40kA 100kA

≤360

mm

≤50k ≥275mm 6m or 8m

2000A 6kV 40kA 100kA

2500A 6kV 50kA 125kA

3150A 6kV 50kA 125kA

4000A 6kV 63kA 160kA

≤600mm

5000A 6kV 63kA 160kA

6300A 6kV 80kA 160kA

8000A 6kV 80kA 200kA

10000A 6kV 80kA 200kA

1kV series products cover 0.4kV

1kV Compound Insulated Shielding Copper Tubular Busbar

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6kV composite shielded insulated busbar

Rated

current

Frequency

withstand voltage

for 1min

Thermal stable

current(4S)

Dynamic

stable current

Bending

radius

Temperature

rise

Phase

space Bus bar span

1600A 30kV 40kA 100kA

≤360mm

≤50k ≥275mm 6m or 8m

2000A 30kV 40kA 100kA

2500A 30kV 50kA 125kA

3150A 30kV 50kA 125kA

4000A 30kV 63kA 160kA

≤600mm

5000A 30kV 63kA 160kA

6300A 30kV 80kA 160kA

8000A 30kV 80kA 200kA

10000A 30kV 80kA 200kA

6kV series products can cover 3kV

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15kV composite shielded insulated busbar

Rated

current

Frequency

withstand voltage

for 1min

Thermal stable

current(4S)

Dynamic

stable current

Bending

radius

Temperature

rise

Phase

space Bus bar span

1600A 55kV 40kA 100kA

≤360mm

≤50k ≥275mm 6m 或 8m

2000A 55kV 40kA 100kA

2500A 55kV 50kA 125kA

3150A 55kV 50kA 125kA

4000A 55kV 63kA 160kA

≤600mm

5000A 55kV 63kA 160kA

6300A 55kV 80kA 160kA

8000A 55kV 80kA 200kA

10000A 55kV 80kA 200kA

15kV series products cover 10kV

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20kV composite shielded insulated busbar

Rated

current

Frequency

withstand voltage

for 1min

Thermal stable

current(4S)

Dynamic

stable current

Bending

radius

Temperature

rise

Phase

space Bus bar span

1600A 65kV 40kA 100kA

≤360mm

≤50k ≥275mm 6m or 8m

2000A 65kV 40kA 100kA

2500A 65kV 50kA 125kA

3150A 65kV 50kA 125kA

4000A 65kV 63kA 160kA

≤600mm

5000A 65kV 63kA 160kA

6300A 65kV 80kA 160kA

8000A 65kV 80kA 200kA

10000A 65kV 80kA 200kA

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35kV composite shielded insulated busbar

Rated

current

Frequency

withstand voltage

for 1min

Thermal stable

current(4S)

Dynamic

stable current

Bending

radius

Temperature

rise

Phase

space Bus bar span

1600A 95kV 40kA 100kA

≤360mm

≤50k ≥275mm 6m or 8m

2000A 95kV 40kA 100kA

2500A 95kV 50kA 125kA

3150A 95kV 50kA 125kA

4000A 95kV 63kA 160kA

≤600mm

5000A 95kV 63kA 160kA

6300A 95kV 80kA 160kA

8000A 95kV 80kA 200kA

10000A 95kV 80kA 200kA

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Classic solution

A) Busbar between low voltage side of transformer and switch cabinet

1. First Solution of busbar between the main transformer and high-voltage switch cabinet

2. Second solution of busbar between the main transformer and high-voltage switch cabinet

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3. Third solution of busbar between the main transformer and high-voltage switch cabinet

4. Forth solution of busbar between the main transformer and high-voltage switch cabinet

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5. Fifth solution of busbar between the main transformer and high-voltage switch gear cabinet

6. Sixth kind of solution of busbar between the main transformer and high-voltage switch cabinet

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B) Busbar solution between high-voltage switch cabinets

1. First busbar solution between high-voltage switch cabinets

2. Second kind of busbar solution between high-voltage switch cabinets

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Third busbar solution between high-voltage switch cabinets

3. Forth busbar solution between high-voltage switch cabinets

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Product comparison

Product comparison between, Compound Insulated Shiedling Copper Tubular Busbar, Rectangular type busbar, Cable,

Enclosed busbar

Technical Comparison table between pipe insulated busbar and other conductors

Compound Insulated

Shiedling Copper

Tubular Busbar

Rectangular busbar Cable Enclosed busbar

Carrier flow Largest Large Small Larger

Insulation performance Strong Weak Strong Mediocre

Mechanical strength Highest High Low High

Heat dissipation Best Good Bad Best

Electrical loss Small Big Big Big

Electrical anti-damping Strongest Weak Strong Weak

Ambient anti-interference Strong Weak Strong Weak

Space Small Big Small Bigger

Installation span No supporting

structure, 6-8 meters

Supporting structure,

little span, post insulator

Little span, supporting

structure needed and cable

accessories

Little span, supporting

structure needed

Installation Simple, flexible and

mobile

Complicated, hard to

install

Little bending radius,

complicated installation for

accessories

Complicated and hard to

install

Cost Comparison table between Compound Insulated Shiedling Copper Tubular Busbar and other busbar & conductors

Pipe insulated

busbar Rectangular busbar Cable Enclosed busbar

Busbar cost High Low Low High

Busbar loss Low High High High

Construction cost Low High, supporting

structure needed

Higher, supporting

structure needed

High, supporting and

hanging structure

needed

Installation cost Free High High Highest

Maintenance cost No maintenance,

low cost

Schedule

maintenance, high

No maintenance,

Low cost, hard to locate

the fault

Schedule maintenance,

high

Service life 30 years 15-20 years 30 years 15-20 years

Comprehensive

cost Low Middle Low High

Shandong Taikai Cable Co.,Ltd

2017 1st edition.