10.05.

2019

KNOWLEDGE SHARING
CLEATS & LEADS PROJECT
1ZBA4640-101- REV -F
KIRTIKA MATHUR, PTPT -F1, INABB
4/14/20 1 13127-B2158-TATA POWER HDIL
LOADING GUIDELINE
Case 1:- Normal Cyclic Loading
Permissible temperature for insulated conductors 110°C rated current (In). For bare conductors the permissible
temperature may be 20K higher.
• Based on normal ageing of paper a maximum hot spot temperature of 110°C for paper insulated conductors with
max top oil temperature rise of 65K is valid.
• For bare conductors in oil a maximum hot spot temperature of 140°C (oil gassing) with maximum top oil
temperature of 105°C is valid.

Case 2:- Long Time emergency Loading

The temperature for any conductor has to stay below limit of 140°C for given overload.
• Maximum permitted hot spot temperature for insulated conductors is 130°C,at higher paper aging rate.
• Top oil temp should not exceed of 110°C at any time.

4/14/20 Slide 2 1ZBA4640-101 REV-F

THERMAL DIMENSIONING OF ROUND
CONDUCTORS

  • I (permissible) =

• Where Ae = Effective lead Area

• P = Loss power developed in the lead.
• I = Lead Current
• = Lead Temperature
• = Lead material resistivity at lead temperature.

4/14/20 Slide 3 1ZBA4640-101 REV-F

 THERMAL DIMENSIONING OF ROUND CONDUCTORS
For Stranded Flexible Cable
 If

(Temperature difference between hotspot and surrounding oil)

Where
∆
  𝜃 =𝜃 1 − 𝜃 2
ᶿ2= ᶿ0+ ᶿ3
ᶿ0= Ambient Temperature
ᶿ1=Lead Temperature
ᶿ2= Temperature of oil surrounding lead
ᶿ3= Top oil temperature rise
Hence

Via substituting formula:-

4/14/20 Slide 4 1ZBA4640-101 REV-F

Calculation of Permissible current in lead
Ae Effective lead area 400
ᶿ1 Lead Temperature 98
ᶿ3 Top oil temperature rise 39.5
Temperature difference between hot spot and
∆ᶿ surrounding oil ᶿ1-ᶿ2 26.5
ᶿ0 Ambient temperature 32
ᶿ2 Temperature of oil surrounding lead ᶿ2= ᶿ0+ ᶿ3 71.5
Thermal resistance at paper/oil boundary surface for
ᾳ insulated/non insulated executions 125
ρᶿ1 lead material resistivity at ᶿ1 celsius 0.022852941 0.0175

I Lead Current 590

ʎ Paper thermal conductivity 0.146
p Loss of power developed in lead 19.88777206 ρᶿ1*(I*I)/Ae
D2 Outer Dia of cable 45.5
D1 Inner dia of cable 29.5
P Total Power Developed in lead 50.19346199
I1 Permissible lead current 937.308

4/14/20 Slide 5 CRIMPING & BRAZING

Reduction of permissible current in bundle of round conductors

• Vertically running bundles of leads have same permissible current as single leads.
• Horizontal bundle of leads will have reduced permissible current.

• In = k j.I1
K j = Current reduction factor

• Current reduction factor for bunch is calculated as an average of all reduction factors of indivisual current
flowing leads.
• Adjacent leads reduce cooling thereby permissible load current value in actual conductor.
• Only current carrying leads closely connected to bundle of leads are taken into considerations.
• Dissipation sector is considered for all leads in a bunch.
• Not Current carrying leads in a bunch are only used for reduction of dissipation sector they are not included in
determination of “k j ” value.

4/14/20 Slide 6 1ZBA4640-101 REV-F

Thermal dimensioning of bus-bars
• Single rectangular bar
Thermal dimensioning of bus-bars
 • Heat Transfer Coefficient must be halved in value in horizontal running bus-bars in
relation

to vertical running busbars.

• The cooling surface (Acool) can be calculated for singular rectangular bar assuming single
bus-bar is cooled on all 4 sides.

• For double running parallel rectangular bar

SKIN EFFECT ON CURRENT CARRYING LEADS

• Non uniform distribution of current in conductor due to magnetic fields arising from another conducors
nearby.
• Current will not distribute evenly on cross section of the conductor , but flow in the thin layer at the
surface of conductor reducing effective area.
• Ae < A.
Where Ae is effective cross section area of current flowing inside conductor.
A= Total cross section of conductor.
• For single busbars skin-effect reduces effective cross section.
• Skin effect depends on geometric dimensions of busbar.
• Due to skin effect current concentrates on corner area of busbars.
• Skin effect is reduced by increase of temperature.
• Although material resistance, and thereby Losses increases with increase in temperature .
• Hence correction factor “k” has to be multiplied with material resistivity of busbar

• Without this factor total error in effective resistance shall be ±3% within copper temperature range.

4/14/20 Slide 9 CRIMPING & BRAZING

Preliminary bus bar dimensioning based on
current density

• Based on 3D simulations following reference current densities were found .

• These current densities can be applied independently of skin effect.

4/14/20 Slide 10 CRIMPING & BRAZING

4/14/20 Slide 11 13127-B2158-TATA POWER HDIL