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(4)-G77700-S0019-L058-A
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Project:
Gilgel Gibe – II PROJECT

ETHIOPIA
Description:
400 kV SWITCHYARD
DESIGN
REPORT’s & CALCULATION’s
Subject:
Report on Thermal Calculations Performed for

Sizing of Switchyard Conductors
Note:
This report establishes the sizing of conductors on the basis of thermal
calculation for 400 kV Switchyard at Gilgel Gibe II Hydroelectric Project,
Ethiopia.
Conductor Selection Design Report : Thermal Calculation Page: 3 of 7
Handling: Unrestricted
Contents
page
1. Introduction ....................................................................................................................... 4
2. System Data...................................................................................................................... 4
3. Conductor Data ................................................................................................................. 5
4. Other referred and assumed design inputs....................................................................... 5
5. Attachments ...................................................................................................................... 6
6. Conclusion ........................................................................................................................ 6
7. References........................................................................................................................ 7
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of a utility model or design, are reserved.
(4)-G77700-S0019-L058-A
1 Introduction
The thermal calculation for conductors may be broadly divided into two categories:
a. Continuous Current Carrying capacity
The current carrying capacity of a conductor is the maximum steady-state current inducing a
given temperature rise in the conductor, for given ambient conditions. The continuous current
carrying capacity depends on the type of conductor, its electrical resistance, the maximum
allowable temperature rise and ambient conditions. The conductor ampacity is limited by the
conductor’s maximum operating temperature. The temperature of a conductor depends upon
the balance of heat input and output. The conductor in an outdoor switchyard gains heat
mainly from solar radiation incident on it and the heat generated by Joule effect. Conductor
looses heat by radiation and convection from its surface. This relationship is expressed in the
Heat balance Equation which in turn gives the value of allowable magnitude of current
through the conductor (for details refer detail calculation).
b. Short Circuit Current Carrying Capacity.
A conductor’s temperature will rise rapidly under fault conditions. This is due to the inability of
the conductor to dissipate the heat as rapidly as it is generated. The magnitude and duration
of short circuit fault current that can be sustained by the conductor depends upon the
electrical conductivity and area of cross-section of the conductor withstanding the fault
current. This fault current withstanding capacity is limited to the maximum allowable
temperature rise of the conductor based on its material properties beyond which the
conductors become vulnerable to annealing. In the present calculation, the conductor area
necessary for withstanding the fault current for the given time duration is determined
considering final conductor temperature limited to 2000 C.
2 System data
400kV AC Switchyard
Nominal System Voltage 400 kV
System Frequency 50 Hz
Short Circuit Fault Current at Bus 31.5 kA
Duration of Fault Current 1 sec
Average (daily ambient) temperature 350 C
Maximum Operating Temperature 800 C
Altitude above sea level >1500 m
(4)-G77700-S0019-L058-A
3 Conductor Data (from technical data sheets attached)

A. Flexible conductor
i) 954 MCM ACSR Conductor
Conductor Diameter 30.42 mm
Total Cross-sectional Area of Conductor 547.34 mm2
AC Resistance at 250 C 0.0597 ȍ
B. Rigid Conductor
i) 250/6mm Aluminum Tube (AlMgSi0.5F25)
Outer Diameter 250 mm
Wall thickness 6 mm
Cross –Sectional Area 4600 mm2
Electrical conductivity 28.0 m/ ȍ -mm2
ii) 120/8mm Aluminum Tube (AlMgSi0.5F25)
Wall thickness 8 mm
iii) 120/6mm Aluminum Tube (AlMgSi0.5F25)
Wall thickness 6 mm
(4)-G77700-S0019-L058-A
4 Other referred and assumed design inputs

a. Calculation for flexible conductor :
1. Solar radiation absorption coefficient 0.5 (as per Cl. No. 3.10 of
IEC 1597 : 1995)
2. Intensity of solar radiation at site 900 W/m2 (as per Cl. No.
3.10 of IEC 1597 : 1995)
3. Emissivity coefficient of conductor with respect black body 0.6 (as per Cl. No. 3.10 of
IEC 1597 : 1995)
4. Minimum wind speed at site 1.0 m/s (assumed)
5. Temperature coefficient of electrical resistance of conductor 0.00403 per Deg C
6. Specific Heat for ACSR conductor 0.2469 g-calories/ 0 C
7. Specific weight of Aluminum 2.703 g / cm3
8. Electrical resistivity of Aluminum 2.617 x 10-6 ȍ -cm2/cm
b. Calculation for rigid conductor :
1. Solar radiation absorption coefficient 0.5
2. Maximum operating temperature of conductor 80 0C
3. Emissivity coefficient of conductor with respect black body 0.5
5 Attachments
Attachment-1: Calculations of Continuous Current Carrying capacity for 954 MCM Cardinal
Conductor.
Attachment-2: Check for Short Circuit Current Withstanding Capacity of ACSR Conductor
Attachment-3: Check for Continuous Current Carrying Capacity of 250/6mm Al Tube
Attachment-6: Check for Short Circuit Current Withstanding Capacity of Al. Tubes
(4)-G77700-S0019-L058-A
6 Conclusion
1. Flexible Conductor: From the calculation it is inferred that Twin 954 MCM ACSR with a derated
continuous current carrying capacity of 2287 Amps is suitable for all types of connections with
flexible conductors i.e. conductors incoming and outgoing to the switchyard at the Transformer &
OHL Feeders, equipment connection droppers, jumpers etc and the Jack Bus at the Coupling
Feeder along with the droppers & jumpers associated to it. The conductor is capable of with-
standing fault current upto 31.5 kA for 1 sec duration in the configuration mentioned above.
2. Rigid Conductor: From the calculation it is inferred that the all of the selected tubes can carry
more than 2000 Amps of current continuously at 80 0C temperature and can withstand fault cur-
rent of 31.5 kA for 1 sec. Thus the selection of tubes for switchyard design may now entirely be
attributed to their mechanical properties for various spans of installation. With a conservative
consideration of current carrying capacity the following selection is adopted in further
engineering:
x 250/6 mm AlMgSi0.5F25 Tubular Bus bar to serve as Main Bus Conductor.
x 120/8 mm AlMgSi0.5F25 Tubular Bus bar to serve as Equipment Bus Conductor at the
Bus Coupling feeder.
x 120/6 mm AlMgSi0.5F25 Tubular Bus bar to serve as Equipment Bus Conductor at the
Transformer & Line feeders.
7 References
1. IEC 1597 :1995 Overhead electrical conductors – Calculation methods for stranded bare
conductors.
2. IEEE Std 605 : 1987 IEEE Guide for Design of Substation Rigid-Bus Structures.
3. Technical Data sheet for 954 MCM Cardinal Conductor: Manufacturer – HASCELIK
4. Technical Data sheet for Aluminum Alloy Tubular Conductor: Manufacturer – Corus.
5. CBIP paper on ‘Overload & Fault Current Limitations of Aluminum Conductors.
6. Aluminum Busbar – A.G. Thomas & P.J.H. Rata
(4)-G77700-S0019-L058-A
S (4)-G77700-S0019-L058-A
Attachment - 1
CALCULATIONS OF CONTINUOUS CURRENT CARRYING CAPACITY

FOR 954 MCM CARDINAL CONDUCTOR
Reference Document : IEC 1597.
1. The heat balance equation is : Pj + Psol = Prad + Pconv ……(1)
where,
Pj is the heat generated by Joule effect
Psol is the solar heat gain by the conductor surface
Prad is the heat loss by radiation of the conductor
Pconv is the convection heat loss
2. The power loss, Pj, due to Joule effect is given by : Pj = R T . I 2 ……(2)
where,
RT is the electrical resistance of conductor at a temperature T (:/m)
I is the conductor current (A)
The value of AC resistance at 25oC is = 0.0597 :/km

5.9700E-05 :/m
Therefore AC resistance at 800 C is RT2 = 7.2500E-05 :/m

(As per Table B.6 of IEC:1597)
The value of RT2 will be substituted in equation 2 and value of I will be found. Refer Equation 8 below.
3. The solar heat gain, Psol, is given by : Psol = J . D . S i ……(3)
where,
J is the solar radiation absorption coefficient = 0.5
D is the conductor diameter = 0.03042 m
2
S i is the intensity of solar radiation = 900.00 W/m
Hence, Psol = 13.69 W
4. Heat loss by radiation, Prad, is given by : Prad = s . S . D . K e . (T24 - T14) ……(4)
where,
s is the Stefan-Boltzmann constant = 5.67E-08 W.m -2.K-4
K e is the emissivity coefficient in respect to black body = 0.6
T 1 is the ambient temperature = 35oC = 308 K
T 2 is the final equilibrium temperature = 80oC = 353 K
Hence, Prad = 21.22 W
Gilgel Gibe II Hydroelectric Project 1

S (4)-G77700-S0019-L058-A
5. Convection heat loss is given by : Pconv = O . Nu . (T2 - T1) . S ……(5)
Nu is the Nusselt number and is given by the equation : Nu = 0.65Re0.2 + 0.23Re0.61 ……(6)
Re is the Reynolds number and is given by equation : Re = 1.644x109.v .D [T1+0.5(T2-T1)]-1.78 ……(7)
where,
O is the thermal conductivity of the air film = 0.02585 W.m -1.K-1
in contact with the conductor
T 1 is the ambient temperature = 35oC = 308 K
T 2 is the final equilibrium temperature = 80oC = 353 K
v is the wind speed (minimum) = 1 m/s
=> Re = 1640.347
=> Nu = 23.887
Hence, Pconv = 87.29 W
6. The steady-state current carrying capacity is : I = [(Prad + Pconv - Psol)/RT2]1/2 ……(8)
Where,
Prad = 21.22 W
Pconv = 87.29 W
Psol = 13.69 W
RT2 = 7.2500E-05 :/m
Hence, a Single conductor

can carry a continuous current I # 1144 A
Therefore,
954 MCM Twin Cardinal conductor is capable of carrying a continuous current # 2287 A

S (4)-G77700-S0019-L058-A
Attachment - 2
CHECK FOR SHORT CIRCUIT CURRENT WITHSTANDING CAPACITY of ACSR CONDUCTOR
Reference Document : CBIP paper on 'Overload and Fault Current limitations of Aluminium Conductor'
Designation of cponductor : 954 MCM Cardinal ACSR
Maximum Fault Current that can be allowed to flow through the conductor with it's final temperature within
the limits determined by it's mechanical properties is given by :-
I/n = 3.105 A [{(C x G )/(D x U x t)} x log10{Tf + 228.1 / Ti + 228.1}]1/2 A

where, ………………(1)
I = Maximum allowable rms value of fault current (A)
n = number of subconductor
2
A = Conductor cross-sectional area (in )
0
C = Specific heat of ACSR conductors (gram-calories / C)
G = Specific weight of Aluminium (grams / cm )
3
D = Temperature coefficient of electrical resistance of conductor ( per deg. C)

U = Electrical resistivity of aluminium strands (:-cm /cm)
2
t = Duration of fault (s)

0
Tf = Allowable final conductor temperature ( C)
0
Ti = Conductor temperature at fault initation ( C)
Therefore, for a system with given fault level, the cross-sectional area of the conductor suited to withstand the fault
current for the defined duration and within the allowable final temperature is determined from the equatioin above as :-
A = (I/3.105n) x [(D x U x t ) / {(C x G) x log10{(Tf + 228.1)/(Ti + 228.1)}]1/2 in

2
………………(2)
Now, for the given system the values are :-
I = 31500 A
n = 1
C = 0.2469 g-cal/0C
G = 2.703 g/cm3
D
0
= 0.00403 / C
U = 2.617E-06 :-cm2/cm
t = 1 sec
0
Tf = 200 C
0
Ti = 80 C
=> A = 3.37 cm2
Therefore, required Cross-sectional Area of the conductor suited to withstand the fault current for the defined duration and
within the allowable final temperature of the conductor
2
A = 337.42 mm
Now, Cross-sectional Area of selected conductor

2
At = 547.34 mm
At < A
Hence, actual cross-sectional area of the conductor, At (547.34 mm2) is more than the required cross-sectional area
A( 337.42mm2). Thus selected conductor is capable of withstanding the Short Circuit Fault Current safely
Gilgel Gibe Hydroelectric Project 1

S (4)-G77700-S0019-L058-A
Attachment - 3
CHECK FOR CONTINUOUS CURRENT CARRYING CAPACITY of ALUMINIUM TUBE
Reference Document : IEE 605

Designation of tube : AlMgSi0.5F25 (250/6mm)
Design Inputs :
a. Outer Diameter of tube = 250 mm
b. Wall Thickness = 6 mm
c. Cross-sectional area = 4600 mm2
d. Electrical conductivity = 28 m/:mm
e. Design Ambient Temperature Ta = 35 0
C
f. Maximum Operating Temperature Tf = 80 0
C
g. Temperature coefficient of resistance D = 0.000125 :mm.
1. The heat balance equation is : I2RF+qs=qc+qr+qcond ……(1)
where,
I
2
2. The power loss, I RF, due to Joule effect is given by : Pj = I2RF ……(2)
Outer Diameter of tube d = 9.85 inch

Thickness of Tube t = 0.2364 inch

Electrical Resistivity of tube at 200 C U = 3.5714E-02 :mm /m
Now, Resistance at 200 C per unit length R20 = U / A :/m
= 7.7640E-06 :/m
Resistance at max. operating temperature Rf = R20[1 + D(Tf-20)]
R80 = 7.8222E-06 :/m
= 2.3841E-06 :/ft
Skin effect ratio F
The ratio Rac/Rdc is a measure of the skin effect. For a conductor of given shape, the first step is to calculate : (f/R dc x
1000)^0.5, and then to find the ratio Rac/Rdc for this value from the corresponding t/d curve
Rac = ac resistance at system frequency

Rdc =R dc resistance of the conductor (busbar)
f = system frequency = 50 Hz
t = wall thickness of tube = 0.2364 inch
d = Outer dia. of busbar = 9.85 inch
therefore (f/Rdc x 1000)^0.5 = 144.82

t/d = 0.02
(From (f/Rdc)^0.5 vs t/d

and hence skin effect ratio F = 1.02 curve - attachment 1)
3. The solar heat gain, qs, is given by : qs = 0.00695*['*Qs*A'*K*sin(I) ……(3)
where,
[' is the solar radiation absorption coefficient = 0.5
I= effective angle of incidenceof Sun =
= 90 deg
cos-1*[cosHc*cos(Zc-Z1)] (As per
considering Hc = 87 deg Table-1,
Zc = 0 deg Pg-42,43 :
Z1 = 90 deg IEEE 605)

S (4)-G77700-S0019-L058-A
2
Q s is the intensity of solar radiation = 78.90 W/ft
2
A' is projected area of conductor,Squaer inches per foot = = 118.20 in /ft
12*sin] * conductor size
K = Heat multiplying factors for high altitudes = 1.15 (Table-1, Pg-46) IEEE 605
Hence, qs = 37.27 W/ft
4. Heat loss by radiation, qr, is given by : -12

qr = 36.9*10 *H*A (Tc - Ta4)
4
……(4)
where,
2
A is the conductor surface area = 371.34 in /ft
H is the emissivity coefficient in respect to black body = 0.5
T a is the temperature of = 308 K
35 oC
surrounding bodies in kelvin
T c is the maximum operating 80 oC = 353 K
temperature of conductor
Hence, qr = 44.73 W/ft
5. Forced convection heat loss is given by : qc = d-0.4*A*'T ……(5)
heat transfer is considered at wind speed 2fps and 1 atm pressure

where,
'T difference in temperature in deg C between
= 45.0 oC
conductor surface and ambient temperature
Hence, qc = 66.93 W/ft
6. The steady-state current carrying capacity is : I = [(qr + qc - qs)/RF]1/2 ……(6)
Where,
qr = 44.73 W/ft
qc = 66.93 W/ft
qs = 37.27 W/ft
R65F = 2.4318E-06 :/ft
Hence, a Single AlMgSi0.5F25 (250/6mm) tube

withstanding a 45 0C temperature rise above ambient

S (4)-G77700-S0019-L058-A
Attachment - 4

Design Inputs :
C
C
where,
I
2


= 1.2665E-05 :/m
R80 = 1.2760E-05 :/m
= 3.8889E-06 :/ft
Skin effect ratio F

therefore (f/Rdc x 1000)^0.5 = 113.39

t/d = 0.07

where,
= 90 deg
Zc = 0 deg Pg-42,43 :
Z1 = 90 deg IEEE 605)

S (4)-G77700-S0019-L058-A
2
2

qr = 36.9*10 *H*A (Tc - Ta4)
4
……(4)
where,
2
35 oC

where,
= 45.0 oC
Where,
qr = 21.47 W/ft
qc = 43.09 W/ft
qs = 17.89 W/ft
R65F = 3.9667E-06 :/ft


S (4)-G77700-S0019-L058-A
Attachment - 5

Design Inputs :
C
C
where,
I
2


= 1.6611E-05 :/m
R80 = 1.6736E-05 :/m
= 5.1008E-06 :/ft
Skin effect ratio F

therefore (f/Rdc x 1000)^0.5 = 99.01

t/d = 0.05

where,
= 90 deg
Zc = 0 deg Pg-42,43 :
Z1 = 90 deg IEEE 605)

S (4)-G77700-S0019-L058-A
2
2

qr = 36.9*10 *H*A (Tc - Ta4)
4
……(4)
where,
2
35 oC

where,
= 45.0 oC
Where,
qr = 21.47 W/ft
qc = 43.09 W/ft
qs = 17.89 W/ft
R65F = 5.2029E-06 :/ft


S (4)-G77700-S0019-L058-A
Attachment - 6
CHECK FOR SHORT CIRCUIT CURRENT WITHSTANDING CAPACITY of ALUMINIUM TUBES
Designation of tube : AlMgSi0.5F25 (250/6mm), (120/8mm) & (120/6mm)
Maximum Fault Current that can be allowed to flow through the tubular conductor with it's final temperature within
the limits determined by it's mechanical properties is given by :-
I = 0.144 x 106 A [1/t log10{Tf - 20 + (15150/G) / Ti - 20 + (15150/G)}]1/2 A

where, ………………(1)
I = Maximum allowable rms value of fault current (A)
2
A = Conductor cross-sectional area (in )
G = Conductor conductivity (% International Annealed Copper Standard, IACS)
t = Duration of fault (s)
Tf = Allowable final conductor temperature (0C)
Ti = Conductor temperature at fault initation (0C)
Therefore, for a system with given fault level, the cross-sectional area of the conductor suited to withstand the fault
current for the defined duration and within the allowable final temperature is determined from the equatioin above as :-
Calculation for determination of conductor conductivity
7.76398E-06 :/m
0
Conductor Resistance at 20 C = (from ampacity calculation)
= 2.36634E-06 :/ft
Now, as per IEEE 605, the resistance of aluminium alloys at a temperature is is expressed as :
RT2 = (8.145*10^-4/C'A2)*(1+0.00403*C'*(T2-20)/61) ………………(2)
where C' = Conductivity of Al. alloy in % IACS
2
A2 = Cross-sectional area of conductor in in
2
= 7.13 in
0
Hence deriving from eqn ..(2) for 20 C temperature, the value of C' is calculated as :
C' = 48.28 % IACS
Now from eqn ..(1), the expression for area of conductor is

A = 6.944 x 10-6 I [t / log 10{Tf - 20 + (15150/G) / Ti - 20 + (15150/G)}]1/2 in 2
………………(3)
Now, for the given system the values are :-
I = 31500 A
G = C' = 48.28 % IACS
t = 1 sec
0
Tf = 200 C
0
Ti = 80 C
=> A = 0.63 in2
Therefore, required Cross-sectional Area of the conductor suited to withstand the fault current for the defined duration and
within the allowable final temperature of the conductor
2
A = 405.85 mm
Now, Cross-sectional Area of selected Al Tube

2
At = 4600.00 mm
At < A
Hence, actual cross-sectional area of the tube, At (4600 mm2) is more than the required cross-sectional area
A( 405.85mm2) Thus selected Al. Tube is capable of withstanding the Short Circuit Fault Current safely
The cross-section area of 120/8 mm and 120/6 mm Tubular busbars are 2820 mm2 & 2150 mm2 respectively which
is also sufficiently larger than the area required to carry the maximum fault current. Thus it may be concluded
that the selected tubes are capable of withstanding the Short Circuit fault Current safely.
Gilgel Gibe II Hydro Electric Project 1

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ILETKEN TERMIK HESAPLAR

Gilgel Gibe – II PROJECT

Report on Thermal Calculations Performed for

3. Conductor Data ................................................................................................................. 5

4. Other referred and assumed design inputs....................................................................... 5

a. Continuous Current Carrying capacity

b. Short Circuit Current Carrying Capacity.

Nominal System Voltage 400 kV

Short Circuit Fault Current at Bus 31.5 kA

Duration of Fault Current 1 sec

Average (daily ambient) temperature 350 C

Maximum Operating Temperature 800 C

Altitude above sea level >1500 m

3 Conductor Data (from technical data sheets attached)

i) 954 MCM ACSR Conductor

Conductor Diameter 30.42 mm

Total Cross-sectional Area of Conductor 547.34 mm2

AC Resistance at 250 C 0.0597 ȍ

i) 250/6mm Aluminum Tube (AlMgSi0.5F25)

Outer Diameter 250 mm

Cross –Sectional Area 4600 mm2

Electrical conductivity 28.0 m/ ȍ -mm2

ii) 120/8mm Aluminum Tube (AlMgSi0.5F25)

Outer Diameter 120 mm

Cross –Sectional Area 2820 mm2

Electrical conductivity 28.0 m/ ȍ -mm2

iii) 120/6mm Aluminum Tube (AlMgSi0.5F25)

Outer Diameter 120 mm

Cross –Sectional Area 2150 mm2

Electrical conductivity 28.0 m/ ȍ -mm2

4 Other referred and assumed design inputs

4. Minimum wind speed at site 1.0 m/s (assumed)

5. Temperature coefficient of electrical resistance of conductor 0.00403 per Deg C

6. Specific Heat for ACSR conductor 0.2469 g-calories/ 0 C

7. Specific weight of Aluminum 2.703 g / cm3

8. Electrical resistivity of Aluminum 2.617 x 10-6 ȍ -cm2/cm

b. Calculation for rigid conductor :

1. Solar radiation absorption coefficient 0.5

2. Maximum operating temperature of conductor 80 0C

3. Emissivity coefficient of conductor with respect black body 0.5

Attachment-3: Check for Continuous Current Carrying Capacity of 250/6mm Al Tube

Attachment-4: Check for Continuous Current Carrying Capacity of 120/8mm Al Tube

Attachment-5: Check for Continuous Current Carrying Capacity of 120/6mm Al Tube

x 250/6 mm AlMgSi0.5F25 Tubular Bus bar to serve as Main Bus Conductor.

5. CBIP paper on ‘Overload & Fault Current Limitations of Aluminum Conductors.

6. Aluminum Busbar – A.G. Thomas & P.J.H. Rata

CALCULATIONS OF CONTINUOUS CURRENT CARRYING CAPACITY

Reference Document : IEC 1597.

1. The heat balance equation is : Pj + Psol = Prad + Pconv ……(1)

2. The power loss, Pj, due to Joule effect is given by : Pj = R T . I 2 ……(2)

The value of AC resistance at 25oC is = 0.0597 :/km

Therefore AC resistance at 800 C is RT2 = 7.2500E-05 :/m

3. The solar heat gain, Psol, is given by : Psol = J . D . S i ……(3)

Hence, Psol = 13.69 W

4. Heat loss by radiation, Prad, is given by : Prad = s . S . D . K e . (T24 - T14) ……(4)

Hence, Prad = 21.22 W

Gilgel Gibe II Hydroelectric Project 1

5. Convection heat loss is given by : Pconv = O . Nu . (T2 - T1) . S ……(5)

Re is the Reynolds number and is given by equation : Re = 1.644x109.v .D [T1+0.5(T2-T1)]-1.78 ……(7)

Hence, Pconv = 87.29 W

6. The steady-state current carrying capacity is : I = [(Prad + Pconv - Psol)/RT2]1/2 ……(8)

3. The solar heat gain, qs, is given by : qs = 0.00695['QsA'K*sin(I) ……(3)

5. Forced convection heat loss is given by : qc = d-0.4A'T ……(5)

3. The solar heat gain, qs, is given by : qs = 0.00695['QsA'K*sin(I) ……(3)

5. Forced convection heat loss is given by : qc = d-0.4A'T ……(5)

3. The solar heat gain, qs, is given by : qs = 0.00695['QsA'K*sin(I) ……(3)

5. Forced convection heat loss is given by : qc = d-0.4A'T ……(5)