Tips & News - April 2013

Vol. 17 No. 2 | APRIL 2013 www. hubbe l l powe r s y s t ems . com ENDURING PRODUCTS AND PEOPLE YOU CAN DEPEND ON. TIPS NEWS

TRANSMISSION TOWERS IN BRAZIL In this issue:

The Rio Madeira Project in Brazil A Powerful New World Awaits You HPS Seismic Capabilities

NEWS

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moved its literature requestpage toanonlinestorefront. Visit hubbellpowersystems.com andclickon the request literature tab to finddirectionsonusing theonlinestorefront. Literature isdivided intoproduct categories tomake it easier for you to find. As always, HPS literaturecontinues tobea free resource.

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2

3

12

Build the Largest in Brazil Being built by a consortium of companies, the Rio Madeira Project consists of two 600 kV DC transmission lines.

-45º

-40º

-70º

-65º

-60º

-50º

-35º

-55º

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-5º

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When finished, it will be the largest transmission line in Brazil and one of the largest in the world.

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The Project will cross five Brazilian states, be supported by 10,000 towers and have approximately 47,200 miles (76,000 km) of conductor (ACSR 40/25mm). The two lines will transmit 12.8 GW of power 1,475 miles (2,375 km) from Port Velho to São Paulo. Work on the first line began in 2011 and is nearing completion. Work on the second, parallel line started in middle of 2012 and should be completed in 2013. It will take 6,500 workers to finish and will cost approximately $1.8 billion USD (about $3.5 billion Reais). The first line is owned by three companies: IE Madeira--formed by CTEEP (51%), Furnas (24.5%), Chesf (24.5%). The second will be owned by: NBTE--formed by Abengoa (51%), Eletrosul (24.5%), Eletronorte (24.5%). Support for all Terrains Terrain and soil conditions vary greatly over the course of the line. As a result, tower designs vary: About 80% are single pivot, guyed towers, supported by helical anchors. About 20% are self-supporting (four legged) towers. The type of tower chosen for each location depended on geography (soil conditions) and line route (curves). Some towers are in very remote locations making construction access difficult. When possible, center pivot, guyed towers were used, which lend themselves to the use of helical anchors. There are three manufacturers in Brazil that produce helical anchors, but in lower quantities than HPS produces Chance ® anchors. In February 2011, representatives of HPS Delmar facility in Brazil met with Alta Energia and Schahin. Three companies are building the lines: Alta Energia (33%), Schahin (34%) and Toshiba (33%). PERU LAPAZ CHILE O C E A N O PA C Í F I C O -15º -20º -25º -30º -75º -70º

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are helping support the transmission towers in a

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Fonte:PDE2010/2019-MME

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diverse array of terrains and soil conditions.

Brazil’s demand for electricity is growing by about 4.5% per year. That means by 2021, overall demand will rise from today’s load of 472,000 GWh to a whopping 736,000 GWh—a 56% increase.

To meet this demand, the Brazilian government is building or plans to build as many as 48 new power plants over the next 10 years. Brazil is crisscrossed by rivers and all 48 plants will be hydroelectric with a combined generating capacity of 42,157 MW of power. Most of that (80%) will be generated by 18 new dams in the Amazon River Basin.

Some tower locations were very remote and a challenge to access.

Two are already built. The Jirau dam produces 6.5 GW and Santo Antonio dam produces 6.3 GW of power. Both are in the Port Velho area.

Delmar is an HPS factory and distribution point for such products as arresters, cutouts and substation switches. The plant is located in Tatui, São Paulo. Delmar has been in business for more than 40 years and was acquired by HPS in 2005.

There is just one problem.

HPS suggested the tower-foundation contractors consider Chance® helical piles as an option and provided samples for testing along with quality reports and test results (including torsional loads). The contractors installed the sample helical piles down and performed compression and tension tests. They also contacted for reference other companies using Chance helical piles.

In Brazil, the power-hungry East and Southeast is separated from the massive hydro generating plants in the Northwest by 1,475 miles (2,375 kilometers) of rugged terrain and smaller rivers. So, in addition to building new power plants, Brazil is also in a frenzy of transmission line construction. One of the largest ventures, the Rio Madeira Project, is currently under construction.

Between Schahin Engenharia and Alta Energia, both tension (SS200-square shaft) and compression (RS3500 round shaft for self support tower) were performed in Brazil under the supervision of HPS engineers.

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Fully satisfied, the contractors placed their first order in August 2011. Of the helical piles used on the first line, 50% are Chance ® brand. The first line of the Rio Madeira project has 4300 towers. Of that, 3440 are guyed towers, with 1800 supported by Chance SS200 helical piles. Of 860 self-supporting towers, 250 are supported by Chance RS3500 helical piles.

Testing and Confidence After installation, the contractors tested the majority of the helical piles. On the four legged towers that rest on helical piles, the contractors tested one of the five to seven piles for each leg. On the center pivot towers, the contractors tested every guyed foundation.

Advantages Add Up Brazilian utilities and contractors have been using concrete, driven-pile and precast tower foundations for several years. While technically efficient, these approaches have some disadvantages.

Testing was necessary for two reasons. First, the Brazilian government required it as part of the construction contract. Second, this was the first time the contractors had worked with this type of foundation system and they wanted to confirm the piles would work in the various soil conditions. Testing did reveal a few problems that illustrate the importance of having accurate soil information. At some sites, soil conditions were deceiving. At one such location, a helical pile had been installed to the correct torque resistance, but testing pulled it out. To remedy that, the contractor simply installed the helical pile deeper. At another site, subterranean cavities forced the engineers to abandon a center pivot design and put in a self-supporting tower due to those soil conditions. Circuitous Delivery Route HPS manufactures Chance ® helical piles in Centralia, Missouri, but the product needed to go to the wilds of Brazil. This required an interesting materials delivery route. First packed in crates in Missouri, the helical piles then shipped to a US port and by sea to Santos, the largest port in Brazil. From there, shipments were delivered by trucks over the 150 miles (240 km) to the HPS Delmar facility. From there, the materials were transported to staging areas and construction sites across Brazil — including some destinations as far as 1,800 miles (3,000 km). There were no shipping or delivery problems. Everything arrived on time. Orders were placed well in advance, so HPS could plan manufacturing and transportation. At first, sources in Brazil made deliveries sooner than HPS. By the end of the project, Chance ® helical piles were delivered ahead of schedule and faster than those of local competitors. This high level of service and product performance bodes well for future projects to employ Chance ® helical piles and guy anchors. Their value as a solution for difficult site and soil conditions was well received. All problems were resolved by correcting testing procedures, changing the tower design or readjusting drilling depths (torque).

Comparison of Foundation Types

concrete / precast / driven pile • Requires a lot of cement • Requires a lot of water • Requires large earth moving equipment • Requires large workforce • Significant vibration (Driven Pile) • Large impact on environment • Difficult to install in some weather conditions

helical pile

• Requires no cement • Requires no water • Requires small tractor or backhoe with drive head • Requires small workforce • No vibration • Very little impact on environment • Can be installed in any weather conditions.

Extensive testing was done on the helical piles, including tension tests.

Since most of the towers are in remote locations, helical piles worked very well, and can be used in diverse soil conditions. Very sandy soil at some sites along the route would impede the installation of concrete foundations. Holes dug in sandy soil tends to cave in and require not only shoring but larger mass. Transportation obstacles to other sites would have impaired delivery of concrete and all its related equipment. These problems were overcome by helical piles, requiring one relatively small installation machine and fewer workers. This resulted in significantly lower total labor costs to install helical piles compared to a large concrete foundation for a single tower.

Contractors also ran compression tests.

The international and interpersonal experience of this iconic undertaking established strong ties between all parties involved. Those relationships formed a working foundation certain to continue building in concert with Brazil’s next power line ventures.

Extension rods allow the drive head to drill the helical piles deeply into the ground, until the proper torque is reached.

Helical foundations are easier and faster to install than traditional, concrete foundations. They also require significantly less material and far fewer workers.

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www.hubbellpowersystems.com

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For more information on the newmarketing posters, contact your territory manager or visit: hubbellpowersystems.com/requestliterature

For the last 20 years, Hubbell Power Systems, Inc. has provided application-specific marketing posters to engineers, purchasers, distributors, packagers and linemen alike. They are tacked up in hallways, on office walls, and the back of doors. They've been requested for museums, elementary schools and linemen schools. They are a staple of firsthand education for newbies entering the power industry. With that kind of iconic status, we thought long and hard about updating our posters. After two years of work, we are proud to reveal a brand new world of posters that highlight Hubbell Power Systems. These high-definition posters span the delivery of power including communications, commercial and industrial. Eachmarket walks you through a graphically-rich scene depicting how our products are installed in their environment while showcasing various product lines.

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updates grounding video

TO THOSE WHO CLIMB ™ TOOL CATALOG REVAMPED FOR 2013

release of Revised editions of two popular titles

1

Equipotential Grounding Seminar Classroom instruction covers single-point, dual-point and worksite temporary grounding practices in: Part I – Principles and Development of Methods Part II – Equipment Selection, Research Testing 41:30 minutes with a mid-point break

• First edition with color photos. • User-friendly large section tabs. • Bound volume of all tools: Hot-line, construction, grounding. • Product detail given in easier bulleted format. • Full indexing by Catalog No. and Alphabetical listings. The new and improved Chance ® Tools Catalog.

2

In the zone: Equipotential Grounding for De-energized Construction & Maintenance

Actual demonstrations show how to place dual-point and personal grounds on overhead distribution lines. Techniques portrayed help reinforce sound reasons for the methods and step-by-step procedures. 09:35 minutes

Hubbell Power Systems overview, promise and branding | Fargo ® connectors | Ohio Brass ® arresters and insulators | Chance ® tool care, tools for overhead construction and maintenance | Chance ® anchors and foundations | Chance ® overhead and padmounted switches | Chance ® sectionalizers, cutouts, fuse links, factory-formed ties and hot line clamps | USCO ™ switches Other topics in our free video training and application library include

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seismic capabilities

Hubbell Power Systems is committed to providing enduring products – even in the most demanding environments. We provide multiple product lines suitable for high seismic conditions.

PCORE ® Bushings PCORE adheres to the rigorous testing standards and strives to provide the most comprehensive selection of 15kV through 500kV porcelain bushings available to address the electric industry’s seismic needs. PCORE offers a wide range of products, including 15kV-69kV PRC ® (Paper-Resin-Capacitor) bushings, 25kV-500kV POC ® (Paper-Oil-Capacitor) bushings and cost-saving products such SET-Terminals, Bushing Repair and the patented Quick-Link bushing. PRC & POC To meet the IEEE 693-2005 testing requirements, PCORE conducted the highest level of the time history shake-table test on a 500kV-1675kV BIL POC Series II Bushing. The bushing successfully passed the test and exceeded the 2g requirements by 25%making PCORE the first porcelain bushing manufacturer in the world to offer such a strong, seismically-approved design. The IEEE standard allows qualifying equipment by group where PCORE 115kV to 500kV Series II bushings are structurally similar and therefore are also certified to the highest seismic performance level. PCORE 15kV to 138kV bushings are qualified by the static pull tests as defined by the IEEE 693-2005 standard. SET-Terminals The new and improved SET-Terminal is used for faster, safer & more cost effective dielectric testing. The SET-Terminal has a rated static cantilever strength of up to 2500 ft-lbs, more than 300% higher than existing models and can absorb high shock loading in excess of 500g’s with side blades in the open position.

AVR 245kV Switch The USCO ® AVR 230kV 3000Amp Vertical Break Switch meets the IEEE 693 standards for high seismic qualifications. During testing, this switch operated flawlessly even after two rounds of open blade testing – which appears to be a fi rst for group operated switches. Its robust construction, coupled with simple design concepts, provide ease of operation in even the most stressful environments. The AVR group operated air break switch carries a 10 year warranty - the longest in the industry - and is an appropriate, cost-eff ective choice for substations that reside in a seismic-prone region.

performance Qualification Levels

Seismic Qualification Levels

IEEE 693 Qualification Level

Ground Acceleration gs

Response Acceleration gs

IEEE 693 Qualification Level

Ground Acceleration gs

Response Acceleration gs

Qualification Tests for PCORE ® Bushings Time History Shake-Table Test

Low

0.1

0.2

High

0.5

1.6

In 2012, PCORE conducted the highest level of the time history shake-table test on a 500kV POC Series II bushing. During the test, the bushing was shaken at an acceleration of 2.5g (25% higher than the required value of 2g) and the top of the bushing experienced an acceleration of more than 8g. The bushing passed the test which was witnessed and certified by a California-licensed professional engineer. In 2001, PCORE conducted the highest level of the time history shake-table test on a 345kV POC Series II bushing. During the test, the bushing was shaken at an acceleration of 2g and the top of the bushing experienced an acceleration of more than 6g. The bushing passed the test which was witnessed and certified by a California-licensed professional engineer. As IEEE 693 allows “qualifying equipment by group” in 4.7 and PCORE 115 kV to 500 kV POC Series II bushings are structurally similar, all PCORE 115 kV to 500 kV POC Series II bushings are certified to the highest seismic performance level. Static Pull Test PCORE 15kV to 138kV bushings passed the static pull tests. During the test, the applied force is much higher than the required value (which is double bushing weight). This test is also much more stringent than the requirement for the inherently acceptable calculation for 15kV and 25kV bushings. RESULTS All PCORE 15 kV to 138 kV bushings are qualified by the static pull tests. PCORE 115 kV to 500 kV POC Series-II bushings are qualified to the highest performance level by the time history shake-table test.

Moderate

0.25

0.8

Performance

1.0

3.2

MVN Arrester Key parameters affecting the seismic capability of arresters are the grade of porcelain used, the thickness of the housing walls and the overall mass and center of gravity of the arrester. The MVN arrester supersedes the original VN arrester with 40% stronger casting, a redesigned base and reduced overall height, making it the arrester of choice for high seismic regions. To be qualified to the high seismic performance level, IEEE 693-2005 requires that an arrester be tested to the 1.0g ZPA level, survives the shake-table test with no structural damage, and that it remains functional, as demonstrated by successfully passing routine produc- tion tests after the shake-table test. These tests consist of measurement of reference voltage, partial discharge and watts loss, and performance of seal-leak tests. RESULTS MVN porcelain ANSI arresters as well as MH3 and MH4 porcelain IEC arresters up to three stacked units are qualified to High Seismic Performance.

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