Energy Division

Raychem Insulation Enhancement Systems

Based on Tyco Electronics Raychemlong experience in polymer technologyand sealing systems for energy net-works we developed an Insulation Enhancement System comprising ofeasy-to-install insulating tubes, sheets,molded parts and tapes for indoor andoutdoor applications. The system permits clearance reduc-tion, flashover protection against accidental bridging of busbars andprevents pollution flashover of insula-tors and bushings. It is ideal for bothenclosed and exposed bus work andfor connections in high voltageswitchgear, substations and electricalapparatus.

Protection from bird and animal outagesBirds and animals often intrude into substations and interfere with overheadlines, causing faults by bridging airclearances. Outages occur especially inmedium voltage substations, whereconductor spacings were not designedfor this risk. The Raychem system ofheat-shrinkable tubes, tapes and sheets,and pre-formed covers and barriersprovides a proven, cost-effective, easy-to-install, retrofit solution to birdand animal outages. It also alleviatesthe impact of electricity networks onwildlife. The heat-shrinkable productsprovide range-taking to simplify product selection and cope with a widevariety of conductors, busbars, connec-tors, insulators and bushings. Wallthickness is controlled by the heat-shrink process. The pre-formed partsare quick and easy to install, and caneven be custom designed. There is noneed to derate busbars or contacts.

Asset protection for outdoor equipmentNetwork reliability is a priority for electrical utilities. Supply interruptionsadd to maintenance costs and affectcustomer satisfaction. Bus faults insubstations can engulf the closelyspaced bus, which in turn can createshort circuit currents sufficient tocause eventful equipment failures.Such an outage can cost more than amillion dollars for equipment replace-ment, labor, environmental clean-upand lost revenue.

We can help utilities avoid un plannedoutages. For over 20 years our products have been protecting substations and overhead lines aroundthe world, by retrofit upgrading of insulation levels. Retrofit upgradingmeans utilities can enhance systemreliability by preventing interruptionscaused by birds and animals or environmental conditions.

Raychem Insulation Enhancement System

The complete retrofit system

The Raychem Insulation EnhancementSystem includes products for substa-tions and overhead lines, for distribu-tion and transmission applications. Allproducts in the insulation enhance-ment system use our crosslinkingpolymer technology that has givenour electrical products superior performance and reliability for over30 years.

Protection from environmental conditionsEnvironmental conditions can drama ti -cally affect the performance of outdoorinsulation. Flashovers can occur duringrainstorms or live-line washing, even in light pollution. They also occur when contamination builds up on thesurface of an insulator above the designspecification. This happens in many environments, including industrial regions, coastal areas and deserts.The solution is retrofit upgrading. Raychem Creepage Extenders provide a unique, long-term answer to pollutionflashovers by permanently increasing the creepage length and improving the shape of the insulator. RaychemBooster Sheds provide a solution toheavy-wetting flashovers, proven byover 20 years of service experience.

The Raychem Insulation EnhancementSystem is widely used for electrical insulation needs on enclosed busworkand for connections in switchgear andelectrical equipment. Whether theequipment is re-engineered or newbusbar systems are designed, the insulation products can provide ahighly flexible system for all shapes and sizes of conductor. The benefits of using the Raychem Insulation Enhancement System are considerable:

• complete system of products forround and rectangular busbars, connections and complex shapes

• simplified product selection and system engineering

• reduced space requirements for electrical equipment of up to 50%

• consistent, reliable installation

• system current rating is unaffected

• resistant to solvents, mechanical impact and wheathering

• compatible with conventional insulating materials

• based on non-tracking, non-halogen,flame-retardant materials

• over 20 years of successful operatingexperience

• Raychem assistance and support fortesting and applications

Medium Voltage System

Low Voltage System

Indoor equipment

Performance specification

Depending on the application, the family of Insulation Enhancement Products can be used on system volt-ages up to and over 36 kV. Followingare the typical test results to show thesuitability of the material when installedaccording to our installation guidelineson 24 kV busbar systems:• AC voltage withstand, Up = 24 kV

for 1 min.• AC leakage current, IL 0.5 mA

at 24 kV AC• No activity or flashover at salinity

level 18 mS/cm at 23°C and 13 kV for500 h

Samples were tested with the metalelectrode attached directly to the outer surface. A test report PPR 840summarizes the test procedures and is available from your local representa-tive. Standard

PE-material (black)

BBIT

Recommended clearances

Tests on busbars insulated with BBIT/BPTM tubing have shown significantreductions in air clearance over con -ventional air-insulated systems.

The most important requirements forthe minimum spacing of the busbarsis that the system must be free fromaudible corona at the AC withstandtest voltage and withstands the im-pulse test voltage.

The illustration on the right shows thepossible air clearances and is basedon practical testing on a range of busbar sizes and configurations. Thedetailed clearance reductions and theapplication ranges for each of theproducts are listed in the data sheets. Further application data are availablefrom your local representative and inour test reports.

Surface of PE-material (black) after48 h testing

Test configuration

Design Requirements

The resistance to UV-light, track anderosion of the insulation materials is of special importance to ensure thesystem performance over decades inservice. The extraordinary outdoorproperties of Tyco Electronics Ray-chem materials have been proven byextensive comparative tests and theirlong experience over more than 25years. Further material data are listed in the product data sheets. Test reportsare available from your local represen-tative.

The importance of track resistance of the materials is demonstrated by the following test configuration:A bare conductor is connected to a post insulator and covered by a non-track resistant heat-shrinkable tubing(PE-material). Only the connection areato the insulator is covered with trackresistant material (BBIT tubing).After testing in a salt fog chamber, a typical test procedure for outdoor terminations, the non-track resistantmaterial shows already after 48 hoursclear marks of erosion and the insula-tion is damaged over its entire length.The BBIT tubing is however fully functional.

IEC 71-2 air clearance

BPTM- insulated system

BBIT-insulated system

Substations BBIT/BPTM busbar insulation tubingBBIT/BPTM heat-shrinkable tubings are suitable for use on long runs of rectangular or round busbars. Thesetubings shrink down to 40% of theiroriginal diameter and, due to excellentflexibility, conform tightly to a widerange of sizes. BBIT/BPTM tubings canbe slid easily into place, even aroundseveral bends and on awkward shapes.Wall thickness is controlled by theheat-shrink process. Available for bus-bar sizes from 6 mm to over 250 mm.BPTM is suitable for applications up to24 kV. BBIT is suitable for applicationsup to and over 36 kV.

HVBT busbar insulation tapeHVBT heat-shrinkable tape is ideal foruse on complex shapes and wherebusbars cannot be disconnected.HVBT tape shrinks 30% longitudinallyand an adhesive layer flows and sealsthe layers of tape during installation.As with the other components in thesystem, the adhesive does not bondto metal work, allowing easy removalfor inspection and maintenance. Available in four widths from 25 mmto 100 mm. Suitable for applicationsup to 24 kV in two layers.

HVIS insulating sheetHVIS heat-shrinkable sheet shrinks25% in both directions enabling rapidand reliable insulation of T-joints, L-joints and difficult shapes. The sheet isa two layer laminate with a heat-shrinkable backing and a hot-melt ad-hesive. The HVIS sheet is cut to sizefrom a roll, held in place around theconnection with metal clamps andshrunk with a gas torch until the ad-hesive flows, sealing the interfaces.Environmentally sealed joints can bemade using our sealing mastic. Suit-able for applications up to at least 36 kV in two layers.

Substations SMOE insulation kitsSMOE insulation kits are designed fortypical busbar connections to supportinsulators and transformer bushingsand for bent T-connections where tubing, tape or sheet cannot be used.SMOE insulation kits consist of a non-shrinkable premolded insulation cover,heat-shrinkable tubings, polypropylenesupport rings and sealing mastic. The non-shrinkable cover is simply laidaround the connection area over thesupport rings and fixed in place byheat-shrinkable tubings which seal alsoto the busbars. Suitable for applica-tions up to at least 36 kV.

BISG squirrel guardsThe BISG squirrel guard is a rigid polymeric disc which fits between the sheds of post insulators and equipment bushings to prevent animals, such as squirrels and cats,from bridging the phase-to-groundclearance. The animal must climb ontothe squirrel guard before touching thelive conductor. Installation is quick andsimple, with no need to disconnectbusbars, and can be done live-line. Onesize is available to fit core diametersfrom 60 mm to 115 mm. Suitable forapplications up to at least 36 kV.

BCIC preformed partsA wide range of standard BCIC preformed covers is available for connections for insulators, bushingsand busbars. Customized covers canbe made simply and economically byvacuum forming non-shrinkable sheetmaterial. Standard covers can be easilymodified. Installation is very simpleoften with no need to disconnect busbars. BCIC covers are held in placewith UV-stabilized plastic nuts andbolts, rivets or tie-wraps, and can beeasily removed for maintenance, or elsesealed with our sealing mastic. Suitablefor applications up to at least 36 kV.

Overhead Lines BCIC bird protection capThe BCIC bird cap protects birds andother animals from live conductorsmounted on metal or earthed cross -arms. The flexible polymer means thatmost configurations of conductor attachment are easily accommodated.Installation is very simple and tool-free. Suitable for applications on awide range of different insulators upto 24 kV.

OLIT overhead line insulating tapeOLIT is an adhesive-lined heat-shrink-able tape which protects overheadlines against flashovers caused bybirds and animals, swinging conduc-tors and intermittent contacts withtrees. OLIT tape is preformed helicallyto facilitate installation. The adhesivelayer melts when shrunk down, amalgamating the layers to form awrap-around installation tube. OLITtape does not adhere to metal surfaces, allowing easy removal formaintenance. Suitable for applicationsup to 24 kV in two layers.

OLIC Overhead line covers and kitsOLIC is a ”clip-on” insulating channelwhich provides flashover protectionfor overhead lines. OLIC-O sectionsclip over the conductor and are heldin place with UV-stabilized plastic tie-wraps. OLIC-C sections clip overthe conductor and are held in placewith a removable and reusable closure rail. SMOUV insulation kitscombine and adapt standard parts for specific applications such as bushing insulation. Suitable for applications up to 24 kV.

Pollution/Heavy Wetting HVBS booster shedsHVBS booster sheds are loose-fittingcollars for insulators and bushings, which are spaced from the porcelain skirt by short pegs and from the core by tongues. Booster sheds increasethe diameter of the bushing in severalplaces and break up long cascades oflightly contaminated water to prevent”heavy wetting” flashovers, which canoccur during live-line washing or torrential rain. Available to fit insulatorcore diameters from 160 mm to 770 mm, or custom made. Suitable for applications up to 500 kV.

HVCE creepage extendersHVCE creepage extenders represent a long-term solution to pollutionflashovers by making a permanent addition to the creepage distance.This increases flashover voltage andreduces leakage currents and surfaceelectrical stress. Creepage extendersalso improve the insulator shape andincrease the strike distance.

Heat-shrinkable HVCE creepage extenders are flexible polymeric skirts, coated internally with a track-resistant mastic for bonding to theporcelain. These are available to fit insulators and bushings up to 500 kV,with shed diameters from 80 mm toover 390 mm.

Wrap-around HVCE-WA creepage extenders are custom-made from asemi-rigid polymer, and are bonded inplace with a pressure-sensitive track-resistant mastic. HVCE-WA creepageextenders are cold-applied. There isno need to disconnect to install wrap-around creepage extenders.These are available to fit insulatorsand bushings up to 500 kV, with shed diameters from 100 mm to over 1000 mm.

Insulation Enhancement Systems

Our range of insulation-enhancement products includes:

• Substation protection systems

• Overhead line protection

• Pollution and heavy-wettingflashover protection

• Bus insulation for low- and medium-voltage applications

All of the above information, including drawings, illustrations and graphic designs, reflects our present understanding and is to the best of our knowledge and belief correct and reliable. Users, however, should independently evaluate the suitability of each product for the desired application. Under no circumstances does this constitutean assurance of any particular quality or performance. Such an assurance is only provided in the context of our product specifications or explicit contractual arrangements.Our liability for these products is set forth in our standard terms and conditions of sale. Raychem, TE Logo and Tyco Electronics are trademarks.

The Energy Division, a global operating unit of Tyco Electronicsdevelops manufactures and markets products and systemsfor the electrical power industry. Today, the Energy Divisionemploys approximately 4.000 people and annual sales amountto almost $800 million. Our products are extensively employedby power utilities and equipment manufacturers, in rail transportsystems and in industry around the world.

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Tyco Electronics Raychem GmbH Energy DivisionFinsinger Feld 185521 Ottobrunn/Munich, Germany

Phone: +49-89-6089-0 Fax: +49-89-6096345

http://energy.tycoelectronics.com