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A Phoenix Mecano Partner Company

Technology For Electrical Energy

BusbarSolutionsManufactured in Frederick, MD

www.TEFELEN.com

TEFELEN — Technology for Electrical Energy

TEFELEN America, which is an acronym for “Technology for Electrical Energy” is the first American company to design and manufacture low and medium voltage resin based Insulated Bus Pipe (IBP) systems. Together with its strong partner Phoenix Mecano, an international stock-listed technology company, TEFELEN America is working to establish and strengthen the application of resin based insulated Bus Pipe solutions throughout the American market. TEFELEN America’s design and production facilities are headquartered in Frederick, Maryland within Phoenix Mecano’s complex.

TEFELENFrederick, MD

Nation’s CapitalWashington, DC

We are the only IBP Design & Manufacturing Facility in the United States!

Busbar Solutions Technology For Electrical Energy

CONTENTSGeneral Information......................................................................................................................................................................................................... 02

Applications ..........................................................................................................................................................................................................02

Resin Insulated Busbar, Bus Pipe ISOBUS MR .............................................................................................................................................. 03

Range of Electrical Applications ..........................................................................................................................................................................03

Intended Use .........................................................................................................................................................................................................04

Connection Sleeves ..............................................................................................................................................................................................05

Electrical Specifications .......................................................................................................................................................................................06

Fixation Systems ...................................................................................................................................................................................................07

Cast Resin Insulated Busbar, ISOBUS TKL ....................................................................................................................................................... 08

Intended Use ........................................................................................................................................................................................................08

Low and Medium Voltage Systems ......................................................................................................................................................................09

Type Tests/Routine Tests ....................................................................................................................................................................................10

Standard Set of Delivered Equipment ............................................................................................................................................................... 11

Ordering Information ........................................................................................................................................................................................... 12

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ApplicationsPower PlantsGenerator — Generator circuit-breaker — TransformerSwitchgearAuxiliary circuits

SubstationsTransformer — Current limiting reactor — SwitchgearSwitchgear

RenewablesSolar powerWind powerHydro facilities

Offshore Both oil & gas and wind park substationsTransformer — SwitchgearAuxiliary transformer & other equipment

Industrial ManufacturingPetrochemical, Chemical, Metallurgical, Pulp-and-paper, etc.

Civil Engineering ObjectsHigh-rise residential and office buildings, Hospitals, Hotels, Retail and entertainment centers, etc.

Department of DefenseNaval, Coast GuardLand-based Sub StationsDry Docks

ShipyardsCommercial ShipsCruise LinesDoD Applications

031219-N-8157C-040

GENERAL INFORMATION


RESIN INSULATED BUSBAR, BUS PIPE ISOBUS MRRange of Electrical Applications

ISOBUS MR ISOBUS TKL

Type of Insulation Epoxy Resin Impregnated Paper Cast-resin

Nominal voltage AC, kV Up to 36 Up to 24

Nominal current AC, A Up to 12,000 Up to 12,000

Nominal voltage DC, kV Up to 60 Up to 33

Nominal current DC, A Up to 14,000 Up to 18,000

Operating ambient temperature, °C/ °F From -60° to +55°C / -75° to +131°F From -60° to +55°C / -75° to +131°F

Degree of protection Up to IP68 Up to IP68

High chemical resistance Yes Yes

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The basic conductor (1) can be aluminium or copper and either solid or hollow, depending upon amperage. The conductor is wrapped

by alternating insulated crepe paper layers and layers of semi-conducting paper (2) in order to provide the capacitive grading needed.

A vacuum system pulls epoxy resin through the entire length of the element to ensure a void free, partial discharge-free composite dielectric (3) insulation.

The Grounding layer ensures safety while operational (4). To make connections easy between Bus Pipe, and other terminating equipment, there are end

connectors (5) at the ends of each element. Custom end connectors are possible.

For low voltage ISOBUS MR solutions up to 1.2 kV there are no capacitive grading layers and no grounding layer required.

Intended UseThe insulated busbar ISOBUS MR is ideal for medium & low voltage safety critical projects. ISOBUS MR is both electrically and geometrically made to measure according to project specifications. Up to 36 kV & 6,500 A per single phase is possible. It is possible to provide up to 36 kV & 12,000 A. Here we double the busbars per phase. Frequency can be 50 or 60 Hz.

FIGURE 1The Bus Pipe element’s construction drawing1. Conductor (Al, Cu)

2. Capacitive grading

3. Epoxy-impregnated paper wrapping

4. Grounding layer

5. End Connector

3 2 4 1 5

Features• Small overall dimensions, up to 40% less space needed than cable systems

• Tight bending radius, up to 80% tighter bend radius than cable systems

• Designed and built using a modular installation approach

• Suitable for outdoor & indoor applications

• Environmental protection up to IP68, Suitable for marine & wet environments

• High resistance to ultraviolet, aggressive environments

• Low Maintenance

• High degree of fire withstand, passed Navy 3-hour flame test

• No phase to phase short circuit possible

• Partial discharge free

• Modular distribution kit, simply bolted together with no special tools required

• Natural (air) cooling

• Very low power losses (I²R)

• Lowest lifecycle costs for end clients


FIGURE 2The busbar elements connection

1. Busbar element

2. Connecting sleeve

3. Contact spring

4. Flexible

5. Sealing

6. Sealing ring

7. Half flange

8. The connection sleeve's grounding

9. Bellows

10. Clamp

11. Stainless steel sleeve

Connection SleevesSeparate busbar elements are connected to each other by use of bus expansion compensators, which are flexible copper laminate connections. These allow for thermal expansion and contraction. They also allow build tolerances of up to ±2 inches per connection.

The connection is then enclosed by a fully insulated connecting sleeve which has pressure-tight flanges on both sides. In order to balance the potential between the current carrying conductor and the internal surface of the connecting sleeve, a metal ring with contact spring is provided.

Resin insulated Busbar and Bus Pipe ISOBUS MR

1

23

4

57

8

6

a) Indoor application

10

3

12

4

8

9

11

b) Outdoor application

GroundingThe Bus Pipe equipment is individually grounded as follows: the Bus Pipes, connecting sleeves, and the fixing system.

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Manufacturing Process

Manufacturing OptionsVoid-free, Partial Discharge-freeISOBUS MR can be manufactured in lengths up to 30 feet long to almost any geometric shape that fits within our Autoclave. The dimensions of our autoclave systems are 30 ft × 9 ft × 9 ft; below are some examples:

Electrical Specifications

All raw materials are quality checked• Measurement of specific resistance for conductors

• Verification of purity & tearing strength test for insulating paper

• Viscosity, viscosity rise with temperature as parameter, gelation time impregnating resin

Curing in Autoclave is computer monitored• Drying process

• Impregnation process

• Insulation curing and hardening

• Controlled cooling

Internal Quality Checks• Complete project design checks

• Marking, preservation, packaging and completeness checks

• Dimension control checks

Y

Z

X

Straight element L-element Z-element Z-element

Low voltage systems

AC DC

Nominal voltage Up to 1.2 kV Up to 2 kV

Nominal current Up to 12,000 A Up to 14,000 A

Medium voltage systems

AC DC

Nominal voltage Up to 36 kV Up to 60 kV



Dry Dock 8

HMS QUEEN ELIZABETH STUDY• 31% cost savings of for the acquisition and

installation of IBP

• 43% cross-sectional savings for IBP and installation hardware

• 57.7% weight savings for IBP and installation hardware

• Main feeder lines reduced from fifty-four, 300 MCM cables to three IBP

Applications• Navy Shipyard Dry Dock 8 in Norfolk, VA

• Osage wind & Duke Solar farm in Texas

• Phillips 66 Sea Port export terminal in Texas

• RES Windfarm in Oklahoma for ABB

• Several Cruise Ships using IBP

• Royal Caribbean – Radiance class – 4 in service

• Norwegian Cruise Lines – Dawn class – 2 in service

• Celebrity Cruises – Solstice class – 5 in service

• French Mistral class Electric Ship

• Australian Canberra class Ship

• Siemens Marine Solutions, Siemens Schottel Propulsor (SSP)(Azipod)

Fixation SystemsWe use a special computer program to dimension the fixing system, taking into account short circuit current, natural frequency and weight. The distance between the mounting places of the Bus Pipe to the walls, ceiling or floor is calculated, prohibited distances are also calculated. Fixation of the Bus Pipe (Figure 2) to the walls, ceiling or floors is carried out by means of polyamide clamps (1), aluminium x-profiles (2), fixing angles (3) and hardware. Mounting to a wall allows both horizontal and vertical installation of the Bus Pipe. We can also mount to the floor where the project requires it.

A

FIGURE 2Elements of the Bus Pipe mounting

Resin insulated Busbar and Bus Pipe ISOBUS MR

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CAST RESIN INSULATED BUSBAR, ISOBUS TKLIntended Use The compact dimensioned cast-resin busbar ISOBUS TKL is intended for connections in AC & DC circuits.

For AC circuits the voltage range is up to 24 kV and rated current is up to 6,000 A for single line and up to 12,000 A for double line, frequency can be 50 or 60 Hz.

For DC circuits the voltage range is up to 33 kV, rated current up to 18,000 A.

Operating ConditionsISOBUS TKL is intended for operation between ambient temperatures ranging from -60 to +55°C / -75 to +131°F.

The life-span of the product is 50 years.

With degree of protection up to IP68, it’s an optimal solution for marine, offshore & wet environments.

The very high fire withstand >3 hours means that it is perfect for service entrance & risers in civil constructions.

ISOBUS TKL has extreme resistance to chemicals & aggressive atmospheres.

ISOBUS TKL can be easily modified and extended as the facility grows/needs change.

Low voltage systems

AC DC

Nominal voltage Up to 1.1 kV Up to 1.5 kV


Medium voltage systems

AC DC

Nominal voltage Up to 24 kV Up to 33 kV



Connections

Cast Resin Insulated Busbar ISOBUS TKL

• Nominal voltage of up to 1 kV

• Rated currents up to 7,500 A

• Copper or aluminium conductors (from 2 to 10) sealed in one housing made of a special compound

• In the same housing a neutral and/ or a protective conductor can be placed

• Bus bars are completed with holders for the bus bar support during the installation on the metal structures

• Nominal voltage of up to 1 kV

• Rated currents up to 7,500 A

• Copper or aluminium conductors (from 2 to 10) sealed in one housing made of a special compound

• In the same housing a neutral and/ or a protective conductor can be placed

• Bus bars are completed with holders for the bus bar support during the installation on the metal structures

ISOBUS TKLN ISOBUS TKLCLOW VOLTAGE SYSTEMS MEDIUM VOLTAGE SYSTEMS

Low and Medium Voltage Systems

Aluminium Plates (for mounting of

the busbar & screen installation)

Aluminium or Copper Conductor

Busbar Element

Air Gaps for Natural Cooling

Bolted Connection

Casted Connection

ISOBUS TKLN ELEMENT

Copper / Aluminium Connection

Spacer Between Phases

Pressure Plate

Bolt

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Type TestsThe ISOBUS MR Bus Pipe system is a type tested system for which the following tests are performed:

• Temperature rise

• Verification of thermal short-time current withstand

• Verification of dimensions

• Vibration and Shock tests respectively Seismic tests

• Tests for mechanical stability

• Fire tests

• Climate tests to ensure the performance during operation, transportation and storage

• Ingress Protection (IP) tests

Routine TestsAfter manufacturing process, each element of a Bus Pipe system is subject to the following tests:

• Dimensional check of the conductors

• Dry power-frequency voltage withstand

• Measurement of partial discharge quantity

• Measurement of dielectric dissipation factor (tan δ) and capacitance at ambient temperature

• Final visual inspection

Inside testing cage — TEFELEN, Frederick, MD


HARDWARE INCLUDES:• Bus Pipe elements

• Connecting sleeves

• Flexible or high flexible bus expansion compensators for connection of elements to each other and connections of the Bus Pipe to equipment

• Fixation system, including aluminium x-profiles and hardware

• Grounding cable

• Nuts and bolts

• Warranty card

• Test reports

SOFTWARE INCLUDES:• Packing list

• The set of assembly factory drawings

• Installation instruction manual

• Operation manual

• Test reports for each element

PACKINGAccording to the design documentation, Bus Pipes and components are packed and fastened into sturdy wooden boxes. Separately delivered small size assembly units, details and fasteners are packed into wooden boxes according to the design documentation.

Standard Set of Delivered EquipmentISOBUS MR modular distribution kit is delivered on site complete with all components/documents required for installation. The delivery package is created according to design documentation and rigorously checked prior to dispatch. The list below shows the main elements.

Oven and Vacuum System — TEFELEN, Frederick, MD

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Customers are kindly requested to supply the following information in their orders to enable quick processing in the factory:

• Rated voltage

• Rated current

• Sort-circuit currents thermal Ith, dyanmic Idyn

• Frequency

• Max. ambient temperature

• Conductor material (aluminium, copper)

• Available end connection points/facilities

• Definition of Bus Pipe end connector design

• Accurate building drawings including the information of the equipment positions (if available as CAD 2D, 3D files)

• Accurate drawings of the equipment that has to be connected – especially for the Bus Pipe terminal connections (if available as CAD 2D, 3D files)

• Possible fixation installation method (wall, ceiling, floor, steel beam construction)

Ordering InformationTEFELEN is the only American manufacturer of this type of Bus Pipe electrical distribution system. Today, TEFELEN is engaged in supplying Insulated Bus Pipe systems in the United States and surrounding countries. We meticulously oversee the assembly and installation of equipment, as well as maintain warranties on all distributed equipment.

Our specialists are ready to provide detailed recommendations for selection equipment in accordance with your requirements and provide support for development of technical documentation. We offer high-tech, reliable and safe equipment that is proudly manufactured in the United States.


REQUEST FOR QUOTELet us help you find the best Busbar or Bus Pipe solution for your needs.Scan the code below to access our easy online quote form, or call us at 301-696-9411. You can also email our sales team at [email protected] with any questions. We will be happy to walk you through our quotation and production process!

www.TEFELEN.com/brochure-rfq

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7330 Executive Way Frederick, MD 21704

www.TEFELEN.com

Manufactured in Frederick, Maryland

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