Download - Pfisterer

COMPANY MAGAZINE OF THE PFISTERER-COMPANIES IN SWITZERLAND AND SOUTH AFRICA, INCLUDING THE CENTER OF CEMPETENCE (COC) «OVERHEAD LINES» 02/DECEMBER 2009
Business
Europe’s fi rst 500 kV
HVDC overhead line
page 3
Dear Reader
Business
Eskom visit
PFISTERER (Pty.)
page 4
Gathering strength
for the new year
Hans Wicki
Managing Director
The PFISTERER team has a world champion in
its midst! David Tresch from PFISTERER IXOSIL
won the gold medal at the World Bench Press
Championships. Many congratulations to him.
We can draw a comparison between the success
of our colleague, who can lift more than
twice his body weight, and the exceptional
performances we have seen in our companies
over the last year. Perfect training and perfect
timing meant everything, despite a worsening
climate.
Every trainer knows that you need to follow
periods of top performance with some timeout.
So we are going to use the holidays to have
a break and take a deep breath. After all, we
should remember that despite our successes
in 2009, the crisis could also start to have a negative
effect on our industry.
We want to tackle this challenge head on with
renewed strength in the new year.
This Connect edition covers a wide spectrum,
from the Arctic Circle to the Gulf.
We and our customers have worked hard towards
privileged activities such as delivering
to Dubai’s new city railway and the longest
railway tunnel in the world. The Eskom delegation
visit to Pietermaritzburg was another
great honour and endorsement for us. As were
the platform new CKW substation in Littau
and Finland’s 500 kV high voltage DC cable
line, the first on European soil. All these projects
highlight that we can build on our role as
a partner in securing power supply.
As well as thanking you for your powerful
commitment in 2009, I wish you and your families
a very happy Christmas and a fulfilling
and prosperous new year.
Business
Express delivery
to the Arctic Circle
page 6
Business
ISICOMPACT
at EnBW
page 9
Technology
New 2 Direct XL
and KP-Test 5 dual
page 11
People
New Cigre position
for Dr. K. Papailiou
page 12
Structural work at the new Gotthard base tunnel. Trains will pass through here at speeds of up to 250 km/h
(photo: Alp Transit Gotthard AG).
Major contract for PFISTERER SEFAG AG
Crossing the Alps at high-speed
When the Gotthard base tunnel, the second branch of the new Alp-
Transit railway (or NEAT to use its German acronym) is completed at
the end of 2017, high-speed transits will carry up to 50 million tons
of goods through the Alps every day. And PFISTERER SEFAG’s Silcosil
insulators will serve an important role.
Switzerland is the largest transit country
for transporting goods across the Alps by
rail. Thanks for the new NEAT (or Alp Transit)
railway at Lötschberg and Gotthard,
the annual capacity of transporting goods
after production will more than double.
The NEAT features an innovative flat track
at Gotthard and the 34.6 km long base
tunnel at Lötschberg, opened in 2007. The
aim is to halve the amount of HGVs on
roads through the Alps.
The 57 km long Gotthard base tunnel incorporates
two single track tunnels, linked
with cross passages, and two multifunctional
points with emergency stations (a
total of 152 km of tunnel, shafts and passages).
This will make the Gotthard the
longest railway tunnel in the world - a feat
which is likely to stand for many years to
come!
The height of the new tunnel is just 550 m
above sea level and the rocks above tower
up to 2‘300 m. Rock temperatures can reach
40-45 degrees Celsius. Cooling units
lower the working temperature to 28 degrees.
Between the north station at Erst-
Continuation page 2

BUSINESS
Work force at the north portal at Amsteg (photos: Alp Transit Gotthard AG).
feld and the south station at Bodio there
are three transitional tunnelling phases at
Amsteg, Sedrun and Faido. The railway is
set to open at the end of 2017.
After that, trains will pass through the
new Gotthard tunnel and its portal stations
at speeds of up to 250 km/h.
PFISTERER SEFAG is part of the action
At the end of June 2009, the 16.7 Hz Transtec
Gotthard consortium (Balfour Beatty
and Kummler + Matter Zurich) awarded
PFISTERER SEFAG the major contract for
delivering Silcosil insulators in bulk. A total
of eight insulator types are to be installed
in the supporting framework, as supporting
insulators in the feeder and entry
points as well as draught insulators in the
event of irregularities in the chain. The total
order is for 8‘170 insulators.
Trials and tests for draught and distortion
conditions have already been successful.
The excellent test results satisfied our
customer’s confidence in us. The same was
expected of the galvanised end fittings.
The following points won the contract for
PFISTERER SEFAG:
Reference points in the rail tunnel area
(in use at BLS since 1979)
Assessments of 30-year old insulators in
the BLS Scheitel tunnel (see the report
by Dr. Frank Schmuck in June 09’s Connect).
First-rate quality, guaranteeing uninterrupted
usability.
Production site: Switzerland (Malters)
Competitive price.
The necessary approval documentation
is being processed by the Department
of Transport (BAV) as we speak. We are
Happy faces at the contract meeting, from left to right; representatives from PFISTERER SEFAG AG, Walter Bachmann
and Dr. Frank Schmuck, with those from the 16.7 consortium, Jan Villringer (Purchasing Coordinator) and
Hannes Müller (Project Manager).
View of the south portal at Bodio.
2 / 2009 CONNECT 2
expecting a positive decision very soon.
The delivery of insulators is planned
from January 2011 to February 2015. We
have promised our customer that we will
fulfil the order proficiently and promptly
and we look forward to a successful collaboration.
Many thanks to all employees, especially
Walter Fluri and Dr. Frank Schmuck who
contributed to a triumphant sales result.
The incoming order was already celebrated
internally with a drinks evening.
Walter Bachmann
The tunnel system has two 57 km long main tunnels,
various cross passages and two emergency points.

3 2 / 2009 CONNECT BUSINESS
CoC Overhead Lines (OHL): Fenno-Skan expansion project between Finland and Sweden
The fi rst 500 kV HVDC overhead line in Europe!
In response to growing market demands, the electricity cable network
has been expanded in Scandinavia. One of the key projects is the expansion
of the Fenno-Skan HVDC transmission between Finland and
Sweden. This in turn calls for higher performance overhead lines on
both sides of the Baltic Sea.
„Valot Päälla Valtakunnassa“ or „Keeping
the lights on in Finland“ is the slogan on
the Fingrid Oyj website, which operates
the Fenno-Skan transmission together
with the Swedish Svenska Kraftnät between
Finland and Sweden.
Expanding the world’s longest submarine
power cable
When it was opened in 1989, the 200 km
long submarine cable with a voltage of
400 kV became the longest and therefore
most powerful underwater cable
in the world. The Fenno-Skan 2 Link will
add a further 800 MW to the rated power
of 500 MW by mid 2011. The new DC
cable will run from Rihtniemi in Finland
(approx. 60 km north of Turku) to Dannebo
in Sweden (approx. 150 km north of
Stockholm) parallel to the existing cable
in the Baltic Sea.
Environmental protection –
an important topic
Because this expansion was already taken
into account at the time of the original
1989 project, there are limits to the environmental
factors in the sea and on land.
On the Swedish side, a second cable has to
run to the new converter station. But on
the Finish side it is just a matter of fitting
the existing 400 kV pylons with a second
line of cable. A 500 kV high voltage direct
current (HVDC) cable will be added to the
33.3 km long stretch from the end of the
sea cable in Rihtniemi to the converter
station in Rauma.
500 kV HVDC for Finland
To expand capacity on the Finish side, PFI-
STERER SEFAG won the contract for manufacturing
and delivering fittings for all
the 500 kV HVDC insulator chains, 500 kV
connection insulators for all field distancers
insulating the clamping chains for the
four-way lengths of rope.
PFISTERER SEFAG materials successfully
passed all tests and have already been
delivered to Finland, where the work on
the capacity expansion is in full swing.
When it is switched on, this part of the
Fingrid Oy network will be the first 500 kV
HVDC overhead line in Europe - and will,
of course, ensure that the lights in Finland
will not go out!
Ruotsi Suomi
In the the Fenno-Skan sea cable runs between Finland and Sweden at underwater depths of up to 110m.
The cable has no negative eff ect on the skerry landscape.
The Finnish-Swedish project is part of an ambitious
expansion project by Nordel, the cooperation organization
of Nordic electricity transmission companies.
yellow = existing / red = under construction / blue =
planned
Wolfgang Huiber Rihtniemi-Rauma capacity
expansion
Customer: FINGRID Oyi
General company:
ELTEL Networks Oy from Finland
Cabling: 400 kV high voltage direct
current Rihtniemi-Rauma,
Finland
Project: Capacity expansion by integrating
a 500 kV high voltage
direct current cable into the
existing cable
Distance: 33.3 km
Opening: End of 2010

BUSINESS
PFISTERER (Pty.) and Speedcraft: Important contracts met in South Africa
Eskom visit to celebrate signing contract
To mark the 30-year ongoing commitment in the local electrical
industry, a prominent Eskom delegation visited the PFISTERER and
Speedcraft plants in Pietermaritzburg (South Africa) on 27 October
2009. The Eskom visit was to pay tribute to the recent efforts of both
companies.
Eskom Attendees: Brian Dames - Chief Offi cer: Generation Business, Sebastian Musendo - General Manager:
Strategic Sourcing and Procurement, Charles Kalima - Manager: Governance and Compliance, Pierre du Toit - Category
Management Manager: Primary Plant, Henk Langenhoven - Manager: Competitive Supplier Development
Programme, Brenda Changfoot: Commercial Manager: Distribution, Stacy McTavish - Commodity Manager, Tshilidzi
Dau - Sourcing Specialist
Pfi sterer Attendees: Dorothee Hertweck - Shareholder and Member of the Supervisory Board, Dr. Konstantin Papailiou
- CEO PFISTERER Holdings Germany, Dr. Jost Baumgärtner - CFO PFISTERER Holdings Germany, Samuel Ansorge
- Managing Director PFISTERER SEFAG AG and Head of COC Overhead Lines, Manfred Peter - International Sales
Director, PFISTERER INTERNATIONAL AG, Hans Wicki - Managing Director PFISTERER SEFAG AG, Rob Schorn - Managing
Director PFISTERER Pietermaritzburg, Geoff Myburgh - Financial Director PFISTERER Pietermaritzburg, Dave Muller -
Sales Director PFISTERER Pietermaritzburg
Speedcraft Attendees: Orene Mnguni - Managing Director and Shareholder Speedcraft Manufacturing, Farouk
Hanief - Sales Director Speedcraft Manufacturing.
Five-year contract with Eskom
The visit recognized the recent achievements
by the two companies of entering
into 5 year enabling contracts with
Eskom for the manufacturing and supply
of Insulators and Hardware for Eskom’s
385 Billion Rand expansion program. This
major award been made in line with the
Government’s and Eskom’s CSDP Initiatives
for International Investment into
South Africa.
The importance of this program to the Vision
of the Government and Eskom was
further enforced by the inclusion of Mr.
Brian Dames the Chief Officer Generation
of Eskom in the Factory Visit. Part of
the commitment through the Competitive
Supplier Development Programme
(CSDP) was to encourage International
Investment complimented by Technology
back into the country.
Pfisterer acquired Hardware Assemblies
in 2003, a name synonymous with the
Manufacture of Transmission and Distribution
Line Hardware since 1978. This
South African company, based in Pietermaritzburg,
has proudly served the South
African and export markets for over 30
years. The primary objective in the establishment
of the company was to create
a local manufacturer for Eskom who was
able to substitute imported commodities
of the high volume required in the growth
of the distribution network.
PFISTERER’s ongoing investment
The Pfisterer Groups acquisition of Hardware
Assemblies in 2003 came after a
2 / 2009 CONNECT 4
long association going back to the initial
establishment of the company. This consolidation
harnessed and strengthened
the synergies that both companies shared.
The company now forms an integral
part of the Overhead Line Centre of Competence
(CoC) within Pfisterer, as its manufacturer
of low, medium and high voltage
overhead line fittings and hardware.
Since the acquisition by Pfisterer, the
Pfisterer Holding Group has followed a
significant and aggressive capital investment
program into the local entity. This
investment program is still in progress to
further upgrade and enhance, the technical
capabilities of the factories in PMB.
Additional contract for lugs for substations
A further important milestone during
the visit was the signing of the one year
contract for the local manufacture of Substation
Clamps for both Transmission and
Distribution Voltages. This added range of
locally manufactured product to the current
range of product manufactured and
supplied out of Pietermaritzburg elevates
the local Manufacturing Facility to that of
the leading Specialist in the South African
Distribution Market.
The value of contracts over the next 5 years
could well be in the range of 600 million
rand as an absolute minimum. Should
Eskom achieve its intended targets then
this value could be rather modest.
The statement Pfisterer The Power Connection
Could never be truer.
The Team at Pietermaritzburg has been
consistently applauded by Eskom’s staff
for its excellent performance and extremely
high customer service levels. Well
Done Team!
Rob Schorn

5 2 / 2009 CONNECT BUSINESS
PFISTERER INTERNATIONAL: Interesting DEWA contracts for the new Dubai Metro project
Developing markets in the Gulf
With the financial crisis that hit in 2008 and the global downturn in
business activities, the markets in Russia, Asia and the Middle East
also suffered a blow. The drop in oil prices hit oil exports hard. But it
seems that the markets in the Gulf and in the Middle East have been
recovering since Spring 2009.
The upturn in the Gulf is due to the oil
prices which have continued to rise since
the beginning of the year and the countercyclical
state investments in infrastructural
projects. And Saudi Arabia and UAE
are right at the top of the list. Various
construction projects from the private
sector may have been reduced or stopped
altogether, but you just need look at the
Burj Dubai (now the tallest building in the
world at 808 m), the production of the
Formula-1 track, Yas Eiland in Abu Dhabi,
and the opening of the new Dubai Metro,
to realise that key projects in the nonpublic
sector are still finding the funding
they need.
And what about PFISTERER?
It is now harder to cultivate the market
and you have to be more than strongwilled
as some projects are taking longer
to complete. But even in 2009, PFISTERER
managed to win highly regarded contracts
in the infrastructural sector. Two examples
are given below.
SICON screw connectors successfully introduced
at DEWA
After gaining the approval of the Dubai
Electricity and Water Authority (DEWA)
in Dubai, around 5‘000 medium voltage
joints have already been installed with
our SICON screw connectors. Their quick
and easy installation was welcomed with
much approval. We are expecting more
orders in the coming months.
PFISTERER 132 kV and 33 kV fittings used
on the Dubai Metro
The three 132 kV/33 kV transformer stations
of the DEWA network, which secure
the new Dubai Metro’s power supply, are
fitted with PFISTERER end seals.
Our traditional ESG 132 kV distributor
sealing ends were implemented on the
high voltage side of the gas insulated
switching unit and the 132 kV transformer
stations.
The 33 kV medium voltage cables were
fitted with over 900 CONNEX plugs. Migration,
delivery and installation came in
3 M joints installed with SICON on an 11 kV three core cable at the Mirdif construction project in Dubai in September 2009.
three phases. This meant that all partners
involved were able to keep Sheik Mohammed
Bin Rashid’s requested roll-out date
of 9/9/2009 for Dubai Metro.
A look ahead
Other largescale projects, such as the Dohaland
and Pearl Island project in Qatar,
are still in the design or extension phase.
One of the biggest projects in the MENA/
GCC region is the extension of a cross
border railway network.
For example, in the next 5 years, Emirate
Union Railway is looking to spend around
7 billion Euro on building an 1100 km long
national stretch with links to Saudi Arabia
and Dubai all the way to Sohar in
Oman. The Gulf states have budgeted
for this strategically important project
despite the effects of the global economic
crisis.
If all goes to plan, the extension of the
rail network will be completed by 2015
with the help of international consortiums.
This is a project that has great
potential and one which PFISTERER of
course is following with interest. Thanks
to our innovative products and the excellent
cooperation with our customers, we
are best placed for potential orders.
Jose C. Tayeb Perez

BUSINESS
2 / 2009 CONNECT 6
CoC Components: Urgent demand for AI outdoor switching unit lugs at Swedish copper mine
Express delivery of lugs from Malters to the Arctic Circle
PFISTERER SEFAG was assigned with delivering a substantial number
of outdoor switching unit terminals to Europe’s largest underground
copper ore mine on behalf of ABB Switzerland. Thanks to the exceptional
efforts of everyone involved we were able to fulfil the order on
time before the winter.
For decades, PFISTERER SEFAG AG has produced
outdoor switching unit lugs for a
number of customers at home and abroad.
The product range includes aluminium,
copper and bimetallic lugs for a maximum
voltage range of up to 750 kV. As well as
producing outdoor switching unit lugs for
largescale projects, we also produce lugs
in smaller batches, usually with a shorter
delivery date.
This autumn, our team proved once more
that speed is one of our core skills, right up
there next to quality and precision.
“The parts need to be assembled before
the winter sets in“,
Senior Project Manager Gerd Eisenhuth
from ABB Schweiz demanded of us on 2
September, with an open order for aluminium
outdoor switching unit lugs for
a project in Sweden. As the parts had to
be assembled before winter, the emphasis
was put on a shorter delivery time. Two
days later we shipped out the twelve alu-
minium outdoor switching unit terminals,
including reserves and screws. The order
from ABB Switzerland came in on September
8. The total order for 1‘791 lugs for the
Aitik 36 PFC Filter project came to a contracted
amount of around 90,000 francs.
The end customer was the Swedish ore
mining company Boliden Mineral AB. The
terminals had to be delivered to the Aitik
copper mine in Lappish Gällivare, right up
in the north of Sweden.
The schedule was met
Under immense pressure, we put together
the required processing papers and started
producing the lugs as soon as the first
rough cast parts came in. The foundry’s
ability to deliver and the flexibility of our
production unit were stretched to their
limits. The first batch was delivered on 5
October. The rest of the goods were collected
on the Friday evening, 9 October, by
minibus from our site in Malters. As early
as the following Monday, Gerd Eisenhut
Pre-winter assembly of the lugs in the new outdoor switching unit in northern Sweden (photo: ABB Schweiz).
Europe‘s largest copper ore mine
The Boliden Mineral AB’s Aitik copper
mine is located near the Swedish city
of Gällivare, around 60 km north of the
Arctic Circle. At around 2.8 km long and
400 m deep underground, it is Europe’s
largest copper ore mine.
The average copper content is 0.4 % and
small quantities of silver and gold are
also mined.
With investments of close to one billion
francs, the annual output of 18 million
tons has doubled to 36 million. This also
explains the need to build more power
stations.
The extension should prolong the mine’s
lifetime to 2025.
from ABB called us to say that the the
goods had arrived at the construction site
in Gällivare.
When you think that the distance from
Malters to Gällivare is 2‘400 km as the
crow flies, the minibus driver herself surely
deserves a medal for this. Just as the
delivery arrived, the first snow set in on 12
October. But this did not stop assembly
going ahead as planned.
Walter Koch
Bird’s eye view of the Aitik copper mine which has been
running since 1968 (photo: Boliden Mineral AB).

7 2 / 2009 CONNECT BUSINESS
CoC Components: PLUG cable connection system
True sizes show themselves in small dimensions
The PLUG cable connection system, already established in railways, is
also gaining in popularity in our industry. There are many good reasons
for this. And knowledgeable visitors at this year’s Hanover Trade
Fair recognised one of these reasons at first glance.
From April 20-24 in Hall 11 of the world’s
most important technology trade fair, the
VEM Group introduced energy efficient
engine solutions, including a largescale
engine for the steel industry. Ready to
connect, equipped with PFISTERER’s PLUG
jacks and plugs, the powerful exhibition
piece conveyed the key advantage of the
connection system: It takes up very little
room in the industry’s often cramped machinery
areas.
If you are looking for further plus points
of the PLUG compared to conventional
engine terminal boxes, beyond the first
impression, you will not be disappointed.
Systematically installed, the PLUG connec-
tion system safeguards the protection of
system limitations: As you can plug it in
dry, you no longer have to open machines
when you connect them.
Its switch-safe encodable plugs mean you
can replace components both quickly and
securely, so PLUG is an efficient way of reducing
manhours and longterm costs.
Why leading engine manufacturers and
industrial machine operators prefer PLUG:
VEM largescale engines are now in place
in a Thyssen steel plant. They were connected
with the permanent reliability of
36 PLUG systems from PFISTERER.
Gerd Albrecht/Jörg Fries
PLUG cables:
efficient and secure
Pluggable electrical cabling
Voltage values of 1 kVAC / 4 kVAC /
6.6 kVAC
Currents of 400 A/600 A/ 800 A/1250 A
Cable diameter 35 - 240 mm2 Advantages:
Faster, more economical and safer
to install/replace engines,
transformers and machines
Considerably lighter than
conventional connections
Compact dimensions
Encoded plugs and machine
connection (socket) prevents
unreliable polarity
Option of cost-reducing prepackaging
or onsite assembly
Reduction in life cycle costs
Anti-surge and shock tested according
to IEC 68-2-6/27
Certified according to NF F 16 101
Maximum protection class IP 68
according to EN 60529 (DIN 0470)
Housing material: Flame resistant
according to UL94V-0, PBT 20 % GF
halogen-free, UV-resistant/and
aluminium
Different plug sizes to cover a wide
range of usage
Straight and angled versions
Angled versions with metallic casing
(e.g. chip-proof)

BUSINESS
The existing Ruopigen substation had
been in operation since 1965 and has now
been entirely replaced with a gas-insulated
switching unit. With an order amounting
to 1.5 million francs for medium and
high voltage units, PFISTERER IXOSIL was
heavily involved in the rebuild. With a
large part of the order relating to cable
fittings including assembly, unlike a relatively
small portion of the order being for
cables, the order was perfect for IXOSIL.
Another factor was that CONNEX connectors
were built into the GIS system and we
were able to bring a further advantage to
the table compared to our competitors, by
using our own plugs. To top it all we fitted
our IXOSIL outdoor sealing ends onto the
outdoor unit.
Showcase project for both partners
It was clear back in the planning phase
that the Ruopigen substation should be a
showcase for both CKW and IXOSIL. So the
2 / 2009 CONNECT 8
PFISTERER IXOSIL AG: CKW supply station opened
CKW’s Ruopigen substation becomes a showcase
A total of 48 Connex size 5s were installed in 16 SF6 fi elds of which 3 Connex size 5S were not yet connected.
In the last two years the Switzerland based energy company, Centralschweizerischen
Kraftwerke (CKW), has invested over 19 million CHF
in restoring the Ruopigen substation in Littau. Not only did the restoration
reduce it to a quarter of its previous surface area (800 m 2 )
but, by implementing the most technologically advanced network we
could, it should also secure the system‘s high operating safety.
entire team worked rigorously on creating
the best-looking and most practical designs
and fixing solutions for the cable vault.
High quantity, efficiently assembled
From October 2008 to May 2009 two
teams of up to four IXOSIL engineers worked
around 2‘570 hours to install the complete
cable system. We made excellent
progress, due in part to a mild autumn /
early winter and the outdoor unit’s perfectly
built pylon structures. The number
of fittings helped new engineers attach
their parts.
Even our office staff used the opportunity
to take a picture of the work taking
place before their very eyes.
After the high voltage test, Project Manager
Severin Locher handed over a perfectly
running unit to our customer CKW.
The unit was seen by both sides as a great
success and that is clear for all to see.
Petra Arnold
View of the cable vault, fi tted with 5’200 m
630/95 mm 2 , 600m 1000/95 mm 2 and 210 m
240/95 mm 2 Nexan’s XKDCuT cables, 102 m bonding
cables, 420 m fi xing clamps, 147 anchorage clamps and
96 cable ties (photos: CKW/IXOSIL).
123 kV straight joints were used.
Protection from the weather during work.
The outdoor unit’s 45 ESS123-C31 pylons.

9 2 / 2009 CONNECT BUSINESS
ISICOMPACTplus at the EnBW + ISICOMPACT family
ISICOMPACT at EnBW: Practical knowledge
from professionals for professionals
“SAFE AND SIMPLE.” Clear words about a technical innovation, from
the mouths of specialists in the field using it for the first time: On
behalf of power company EnBW, PFISTERER staff provided training
in the summer of 2009 for about 400 fitters in the correct usage of
ISICOMPACTplus. This, the first tap-off clamp ever to be granted approval
by the Employer‘s Liability Insurance Association „Energie Textil
Elektro“ (BG ETE) for work on equipment under tension without
the need for personal protective equipment (PPE), convinced practitioners
in a range of ways, not least through the sheer convenience of
working with it.
The new is very different from the familiar,
so proper explanation is essential. Very
definitely the case when dealing with a
technology which is required to deliver
safety in various different ways: when fitting
tap-off clamps, the health and indeed
lives of specialist personnel are at stake
while, for the equipment, the intention
is to deliver decades of reliable operation
to assure a continuously available and
reliable power supply. The new generation
of ISICOMPACT tap-off clamps from
PFISTERER fulfil both these criteria. In
keeping with its predecessor, known
throughout the sector as the SCK tap-off
clamp, the ISICOMPACT was also successfully
type-tested on various cable combinations,
as defined in DIN VDE 0220 Part 3.
To enable specialists to use these tapoff
clamps, all tested under ideal laboratory
conditions, the ability to use these
on construction sites easily and safely,
PFISTERER utilised its practical knowledge
in two complementary ways. The
user experience gained with the SCK over
many years was incorporated in the development
of the unique product properties
which characterise the ISICOMPACT;
smooth and seamless access to this new
technology is supported by a training
scheme which is aimed at the everyday
working situations encountered by fitters.
This is because real know-how has to
be acquired to make a job easy, and only
correct application of that expertise guarantees
quality and safety.
ISICOMPACT and ISICOMPACTplus:
firmly on the safe
side with every variant.
The ISICOMPACT product family covers
virtually all standard applications on the
market - and does so with far fewer variants
than its predecessor, the SCK: Equipped
with no more than the ISICOMPACTmulti,
users can replace more than SCK
tap-off clamps. The great advantage of
this: greater safety in the application coupled
with simpler logistics.
You can download our ISICOMPACT
product brochure from our website,
www.pfisterer.com.
Both these properties are top priorities
for power companies. And the EnBW is no
exception to this. In the course of a hazard
assessment of possible arcing strengths
during work under tension near transformer
power intake points, the company decided
to have about 400 of its staff trained
in how to fit the ISICOMPACTplus tap-off
clamp. In so doing, the EnBW is following
the systematic approach set out in German
Health & Safety at Work (HSW) legislation:
where potential dangers exist, priority
must be given to the use of technical solutions.
It is only in the absence of technical

BUSINESS
solutions that organisational protective
measures should be adopted.
ISICOMPACTplus closes an application
loophole
The special version of the ISICOMPACTplus
closes what was always, until it came
along, a loophole in this application field:
it can be used when working under tension,
i.e. on live electrical equipment, without
additional PPE to protect operatives
against electrical hazards. Something
which made the work for fitters a great
deal simplier - when they are working
in the confines of a cable trench on protective
mats wearing rubber boots, safety
gloves and a helmet with visor, their
freedom of movement is already fairly
impaired as it is, and in summer temperatures,
the act of installing a tap-off clamp
to electrically live equipment is a seriously
hot and sweaty job.
Work safety as defined in standards
The training courses on the ISICOMPACTplus
held in seven of EnBW‘s regional centres
between June and September showed
fitters how to install tap-offs under
tension in a much more comfortable and
safer way. During these 16 training days,
Frank Weichert, an employee in Product
Management for Connection and Jointing
Materials, Wolfgang Lexa from the Sales
department in Germany and Eduard Neukamm
from the South sales office guided
course participants through the theory
and practice of correct usage of the innovative
tap-off clamp as defined in BGI 862
and BGR A3.
The specifications from BG ETE offer a clear
indication on how to act in order to safeguard
high standards of health and safety
at work: Installation work must always be
carried out by skilled electrical specialists
trained in the fitting of ISICOMPACTplus
who have also received specific training in
how to work on electrical live equipment,
as defined in DIN VDE 0105. In this process,
the assembly instructions drawn up by
PFISTERER and approved by the BG ETE
must be followed, and only defined tools
must be used: The sheath stripping devices
and fanning wedges must be inspected in
accordance with BGI 862 by an independent
test body, while all others must comply
with DIN EN 60 900.
A Convincing Application
At a later point, during the practical training
session, the specialists attending the
course were shown that compliance with
all necessary safety precautions does not
make the task more inconvenient in any
way. At each of three assembly stations,
under the guidance of PFISTERER employees,
three to four people gained hands-on
experience. Positive responses soon followed:
“Just tighten one screw! that makes
it much faster.“ The single-screw solution
met with approval, as did „the installed
torque“. Once this has been achieved, a
shear-head nut shears off the protruding
threaded bolt causing the tool contact surface
to break off automatically.
Frank Weichert confirms that ISICOMPACT
is perfectly able to speak for itself: “Scepticism
in the face of innovation is normal,
especially when tried and tested techno-
2 / 2009 CONNECT 10
logy such as SCK functions perfectly well.
however, anyone who uses ISICOMPACT
for the first time recognises its handling
benefits at every step of the way and all
variants share that property.” Identical designs
of the of upper and lower sections
eliminate any possibility of assembly errors
being made when assembling the clamping
ring. Moreover, their failsafe components
also interlock with one another. This
means that ISICOMPACT can be positioned
very accurately without any scope for losing
components.
Entry-level service work
Something which is mandatory for green
colour-coded ISICOMPACTplus components
is viewed by ISICOMPACT as a service
in respect of all other variants: With its
training scheme, the company assists all
interested users to come to grips with ISI-
COMPACT tap-off technology at their first
attempt. And this also includes tips and
tricks which only practitioners know. For
example, just how useful insulating tape
can be when positioning and securing the
stripped tap-off cable to the main cable. in
contrast to the conventional clamping ring
technique, This handy hint is very simple to
use with ISICOMPACT because there is no
longer any need to strip the insulation off
the tap-off line.
Using this product really does make sense,
as Wolfgang Lexa explains: “With ISICOM-
PACT, we get around a great deal and learn
a lot in the process. for example, at a trade
fair in Dortmund, one visitor to our stand
had this to say: “That is the easiest tap-off
clamp to fit on the entire market.”

11 2 / 2009 CONNECT TECHNOLOGY
New 2DIREKT XL for up to 6 lines:
Innovative screw technology for pressure to suit dimensions
With its new 2DIREKT XL transformer connection clamp, PFISTERER is extending
the application range of the tried and tested 2DIREKT product family
for distribution transformers: Thanks to innovative screw-in-screw
technology, it is able to connect up to six lines with cross sections of 185 to
400 mm 2 . Comfortable and reliable on a long-term basis.
The scope for connecting up to six conductors
at once to distribution transformers
is becoming an increasingly sought
after solution across Europe, e.g. in Holland,
Germany, Switzerland and Italy. For
this reason, PFISTERER with its new transformer
connection clamp, the 2DIREKT XL,
is offering an advantageous alternative to
cable shoes and flat copper rails.
With the 2DIREKT XL, up to six conductors
can be connected up directly, eliminating
the need for cable shoes to be press-fitted,
and for cable sleeves for fine-core cables.
This reduces the amount of assembly
work involved, and lowers the risk of connection
errors. A suitable cover is available
to protect the connection from physical
contact. In addition, the use of 2DIREKT
KP-Test 5 dual: A voltage tester for several voltage levels.
One grid, many voltage levels, several voltage testers. No need however
for the last of those: With the new KP-Test 5 dual, power providers
and maintenance companies can reliably cover several voltage levels
across a range of 1 to 36 kV with just one voltage tester.
The capacitive KP-Test 5 dual voltage tester
is identical in design and build to the
KP-Test 5, but features an additional selection
function between two rated voltage
ranges. This can be adapted to suit the
grid properties of individual countries and
their areas of influence: For Germany, the
most suitable test ranges are 5 to 12 kV
and 20 to 36 kV, while for the area under
British influence, typical test ranges are 3
to 6 kV and 11 to 36 kV.
The decision in favour of two separate test
ranges was taken by the safety technology
development team at PFISTERER in reference
to standard IEC 61243-1. Based on
this, capacitive voltage testers must signal
XL on just two contact points reduces the
transitional resistance levels which in turn
cuts operating losses on the transformer.
To deliver the contact force required for
larger cable cross sections in an assemblyfriendly
manner, PFISTERER developed the
screw-in-screw system. Whereas a large
screw requires enormous torque due to
its friction radius, with the 2DIREKT XL
system, two screws are tensioned against
one another, enabling them to interact
favourably when being tightened down,
thereby achieving a high level of contact
force at low levels of torque. A pressure
plate at the end of the screw provides the
line with reliable protection against damage
caused by contacting.
zero voltage at any voltage measured of
less than 10 % of rated voltage. In contrast
to this, once above 45 % of rated voltage,
they must signal operating voltage or even
overvoltage. For every voltage range, this
results in there being an undefined range,
although this range is virtually never encountered
in practical situations.
On the safe side. Simply at the touch of
the button.
However, this calculation ceases to apply
if applied simultaneously to too many
voltage levels at one time: What is viewed
as residual voltage at low levels of
grid voltage is deemed to be zero voltage
2DIREKT XL:
New clamp. Nine advantages
Direct connection of up to
6 conductors
No press-fitting, no cable sleeves
required
In the clamping range of 185 mm 2
to 400 mm 2
For transformer end apertures
M30 / M42 / M48 / M55
Vertical or horizontal conductor
connection
Assembly-friendly screw-in-screw
system
Cable-protecting pressure plate
Produced with cover for contact safety
The clamp body and screw are
reusable
at high grid voltages. The consequence of
this, to eliminate any element of risk: An
excessively sensitive voltage tester, i.e. an
impractical tool. Or - as occurred with the
KP-Test 5 dual - the voltage range being
sub-divided into two test areas compatible
with safety technology.
The handling of the KP-Test 5 dual has also
been thought out thoroughly: When the
voltage tester is switched on, the first test
range for low voltage levels is enabled,
while switching into the test range for
higher voltage levels involves pressing
and holding down the
pushbutton, i.e. simple
enough but requiring
careful attention
- thereby eliminating
any possibility of switching
accidentally into
the wrong test range.

GROUP
CEO of PFISTERER appointed as Chairman of the CIGRE Study Committee „Overhead Lines“
Soon to be the “most prominent constructor
of overhead lines” in the world
There have been some good news recently from the CIGRE headquarters
in Paris. The Administrative Council of the leading worldwide
Organization on Electric Power Systems appointed Dr. Konstantin O.
Papailiou, CEO of PFISTERER Group, as Chairman of the Study Committee
B2 (Overhead Lines).
CIGRE is one if not the most respected
international professional association
involved in all aspects of technology for
electric power. And so it is of major importance
for the PFISTERER Group to be
represented in CIGRE at the frontier of
developments in this field. Active participation
in the Study Committees and
Working Groups offers to international
companies like PFISTERER a forum to
present their own research work and to
share their experiences with others.
In this sense Papailiou supports the active
engagement of Dr. Frank Schmuck, a
further member of the PFISTERER Group,
as Convenor of Working Group B2.21 (Insulators).
Papailiou, himself a member of
the Study Committee B2, has contributed
to the Working Group „Mechanical Properties
of Conductors and Fittings“ as its
Convenor.
„CIGRE and Overhead Lines have been
since many years an important part of
my life and it is for me a great challenge
to be able to shape Cigre‘s SC B2 future as
its Chairman“, said the CEO of PFISTERER
Group, pleased about this honourable
nomination. André Merlin, President of
CIGRE, congratulated him in a personal
letter and thanked him for his commitment
and dedication to CIGRE in the
role of a Study Committee Chairman. His
term of office will start in August 2010 on
the occasion of the next CIGRE Session in
Paris.
Brigitte Senn
New management / restructuring at PFISTERER Eastern Europe
With experience of and passion
for the Eastern European market
Peter Feldhofer has taken over as Managing Director of PFISTERER
Ges.m.b.H in Vienna. Piotr Matczak was appointed Managing Director
of PFISTERER Sp. z.o.o. in Poland.
Peter Feldhofer took over as Managing Director
of PFISTERER Austria on 1 September
2009. He also heads the sales company
Kereskedelmi Kft. in Hungary as well
as the RepOffice in Czech Republic. The
qualified electrical engineer gained his
superior knowledge of the industry in his
years as Manager at Rockwell Automation
and before that at Elin Transformatoren
GmbH.
Piotr Matczak, very successful in his role
as Sales Director for our Polish company
in Ozarów Mazowiecki (since September
2004), took over as its Managing Director
in May 2009. At 32, Piotr Matczak becomes
the youngest Managing Director in
the PFISTERER Group.
Many congratulations to both of our colleagues
and we wish them further success
in their new roles.
2 / 2009 CONNECT 12
CIGRE
CIGRE (Conseil International des Grands
Réseaux Électriques, engl. International
Council on Large Electric Systems) is the
world’s biggest organisation on electric
power systems and counts more than
6000 members from utilities, industry
and science. CIGRE’s activities are split into
16 areas of technology, each under the responsibility
of a Study Committee, which
is coordinating the studies in their fi eld.
All Study Committees are represented by
their respective Chairman in the Technical
Committee, presently presided by Prof.
Klaus Fröhlich from ETH Zurich.
For more information:
www.cigre.org
PUBLISHERS DETAILS
Company magazine of the PFISTERER companies in Switzerland
and South Africa, including the group division (CoC)
Overhead Lines
17th year of publication – No. 2/2009 – published twice a year
Circulation: 1600/900 copies german/english
Coordination: Barbara Simeon, PFISTERER SEFAG AG,
Werkstrasse 7, CH-6102 Malters, Tel. ++41 41 499 74 79,
Fax ++41 41 499 74 26, barbara.simeon@sefag.ch
Photos: Melanie Amstad
Editorial/Layout: Brigitte Senn, www.amk.ch
Printed by: Engelberger Druck AG
Peter Feldhofer (left) and Piotr Matczak, the two new
Managing Directors at PFISTERER companies in Austria
and Poland.