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Email:
info@qingzhou-cable.com
Tel:
+8618625503172
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+8618625503172
Skype:
+8618625503172
Substation Busbar
Busbar, also known as busbar, is an electrical conductor made from good conductive metal, usually copper or aluminum, with a large cross-section and permanently installed in the transformer station. The main function of the busbar is to conduct electricity from power sources (transformers, generators) to branch bus bars, thereby distributing electricity to other electrical equipment in the substation and power system.
Conductors in substations are categorized based on their mechanical structure and insulation type. They serve as the critical pathways for collecting, distributing, and transmitting electrical energy.
These are solid, inflexible structures that maintain their shape under their own weight.
Tubular Busbar
Description: A hollow, pipe-like conductor, typically made of aluminum or copper.
Advantages: Excellent strength-to-weight ratio, superior heat dissipation, low corona loss (crucial for high voltages), and a clean, compact appearance.
Applications: The preferred choice for main buses in modern high-voltage (HV) and extra-high-voltage (EHV) substations.
Rectangular / Flat Busbar
Description: A solid, flat bar made of aluminum or copper. Can be used as a single bar or in stacked pairs to increase current-carrying capacity.
Advantages: Simple to manufacture and install, easy to make connections.
Applications: Widely used inside Low Voltage (LV) and Medium Voltage (MV) switchgear, distribution panels, and control boards.
These are made of multiple strands of wire twisted together, giving them high flexibility.
Stranded Conductors (Overhead Wires)
Overhead Strain Bus: Used as the main bus in outdoor substations, suspended between structures.
Jumper/Dropper Connections: Flexible links between equipment (like circuit breakers and transformers) and the rigid main bus.
Substation Incoming/Outgoing Feeders: Connecting the substation to overhead transmission or distribution lines.
ACSR (Aluminum Conductor, Steel Reinforced): The most common type. A central core of high-strength steel wires provides mechanical strength, while outer layers of aluminum wires carry the current.
AAC (All Aluminum Conductor): Made entirely of aluminum strands. Used where high tensile strength is not the primary requirement.
Description: Composed of multiple thin wires twisted or stranded together.
Common Types:
Advantages: High flexibility, can absorb vibration and thermal expansion, excellent for long spans and windy conditions.
Applications:
Overhead Strain Bus: Used as the main bus in outdoor substations, suspended between structures.
Jumper/Dropper Connections: Flexible links between equipment (like circuit breakers and transformers) and the rigid main bus.
Substation Incoming/Outgoing Feeders: Connecting the substation to overhead transmission or distribution lines.
Description: Conductors with no insulating coating. They rely on air gaps and support insulators for electrical isolation.
Examples: ACSR, Tubular Busbar, Rectangular Busbar.
Applications: Almost exclusively used in outdoor substations where there is ample space to maintain safe clearance distances.
Description: Conductors covered with a solid insulating material.
Common Types:
Applications: Underground connections into and out of the substation, and for auxiliary power within the substation.
Applications: Gas-Insulated Substations (GIS), indoor substations, and connections where space is extremely limited or safety is paramount.
Insulated Busbars / Busways: Pre-fabricated assemblies with conductors enclosed in insulation (e.g., epoxy resin) and often within a grounded metal housing.
Power Cables: Typically with XLPE (Cross-linked Polyethylene) insulation.
| Conductor Type | Structure | Typical Application in Substations |
|---|---|---|
| Tubular Busbar | Rigid | Main Bus (HV/EHV) |
| Rectangular Busbar | Rigid | Inside LV/MV Switchgear, Control Panels |
| ACSR / AAC | Flexible | Overhead Strain Bus, Jumper Connections, Feeders |
| Insulated Busbar (e.g., for GIS) | Rigid (insulated) | Gas-Insulated Substations (GIS), Compact Installations |
| Power Cables (XLPE) | Flexible (insulated) | Underground Feeders, Auxiliary Power |
In summary, the choice of conductor depends on factors like voltage level, current capacity, short-circuit withstand, available space, environmental conditions, and cost. Tubular busbars and ACSR are the most visible and dominant types in modern air-insulated outdoor substations.
main types of conductors used in substations
A. Rigid Conductors
Tubular Busbar
Application: Main bus in high-voltage substations.
Rectangular / Flat Busbar
Application: Inside LV/MV switchgear, control panels.
B. Flexible Conductors
Stranded Conductor (e.g., ACSR - Aluminum Conductor, Steel Reinforced)
Application: Overhead strain buses, jumper connections.
AAC (All Aluminum Conductor)
Application: Where high tensile strength is not required.
A. Bare Conductors
Examples: ACSR, Tubular Bus, Rectangular Bus.
Application: Outdoor substations (insulated by air).
B. Insulated Conductors
Insulated Busbar / Busway
Application: Compact substations, indoor facilities.
Power Cables
Application: Underground connections, substation outlets.
ACSR (Aluminum Conductor, Steel Reinforced)
Tubular Busbar (Aluminum or Copper)
Rectangular Busbar (Aluminum or Copper)
AAC (All Aluminum Conductor)
Insulated Phase Busbar
Power Cables (XLPE insulated)
Main Bus: Tubular busbar (HV), ACSR (outdoor)
Equipment Connections: Rectangular busbars, ACSR jumpers
Substation Feeders: ACSR (overhead), Power cables (underground)
Bare conductor cables are widely used in the power transmission and distribution industry. Unlike insulated cables, bare conductor cables do not have any insulating layer, which makes them ideal for outdoor applications like power lines and substations. These cables are essential for carrying electrical current over long distances with minimal losses. Let’s dive into the specifics of how they work, their features, advantages, and disadvantages.
Usage Scenarios: Bare conductor cables are primarily used in overhead power lines, substations, and grounding systems. They are suitable for areas where insulation is not required or where environmental factors do not pose a significant threat to the integrity of the conductor.
How They Work: The primary function of bare conductor cables is to conduct electricity. They rely on their conductive material, usually aluminum or copper, to transmit electrical current from one point to another. The lack of insulation allows for better heat dissipation and reduces the weight of the cable.
Features:
High Conductivity: Materials like copper and aluminum provide excellent electrical conductivity.
Durability: These cables are designed to withstand harsh environmental conditions.
Cost-Effective: The absence of insulation reduces manufacturing costs.
Easy Installation: Lighter weight and flexibility make them easier to install compared to insulated cables.
Disadvantages:
No Protection Against Short Circuits: Lack of insulation can lead to short circuits if not properly managed.
Exposure to Environmental Elements: Vulnerable to environmental factors like wind, rain, and corrosion.
Limited Use Cases: Not suitable for applications where insulation is necessary for safety reasons.
Bare conductor cables can be classified based on the materials used, their functionality, and the standards they adhere to.
By Material:
Copper: High conductivity and durability, but heavier and more expensive.
Aluminum: Lighter and more cost-effective, though slightly less conductive than copper.
By Function:
Overhead Transmission Lines: Designed to transmit electricity over long distances.
Grounding Wires: Used for grounding electrical systems.
Busbars: Conduct electrical current within substations and industrial facilities.
By Standards:
IEC Standards: International Electrotechnical Commission standards for global compatibility.
IEEE Standards: Institute of Electrical and Electronics Engineers standards, commonly used in the US.
EN Standards: European standards for electrical conductors.
Bare conductor cables come in various structures and specifications to suit different applications. Here are some widely used models:
AAC (All Aluminum Conductor):
Structure: Made of aluminum strands.
Specifications: Varies in diameter and cross-sectional area. Commonly used in urban areas due to its lightweight.
ACSR (Aluminum Conductor Steel Reinforced):
Structure: Aluminum strands wrapped around a steel core.
Specifications: High tensile strength and used in long-span overhead lines.
AAAC (All Aluminum Alloy Conductor):
Structure: Made of aluminum alloy strands.
Specifications: Combines the benefits of AAC and ACSR, used in environments requiring higher corrosion resistance.
AAC “Oak”: Diameter of 10 mm, cross-sectional area of 80 mm², used for medium-length transmission lines.
ACSR “Hawk”: Steel core with aluminum strands, high strength for long-span transmission lines.
The production of bare conductor cables involves several steps to ensure quality and performance.
Production Process:
Material Selection: Choosing high-quality aluminum or copper.
Wire Drawing: Reducing the diameter of the metal rods through a series of dies.
Stranding: Twisting multiple wires together to form the conductor.
Annealing: Heating and cooling to improve ductility and conductivity.
Testing Methods:
Tensile Strength Test: Ensuring the cable can withstand mechanical stresses.
Conductivity Test: Measuring electrical conductivity to ensure efficient power transmission.
Corrosion Resistance Test: Evaluating the cable’s durability in harsh environments.
Visual Inspection: Checking for physical defects and ensuring proper stranding.
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