1000 A MCC BUSBAR SIZING CALCULATION

PROJECT CLIENT CONSULTANT EPC CONTRACTOR Document ID 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT M/s. K.P.R. SUGAR MILL LTD M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. ISGEC HEAVY ENGINEERING LIMITED KR11-10302-CLC-001

Revision : 01
Date : 24-05-2012

No. of Sheet - 4

1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10

Input Data Type of Panel System Rated Voltage degree of Protection Panel Max. Current Rating in Amp (Design) Fault Current & Duration (KA RMS Symmetrical for 1 Sec.) Ambient Temperature (Deg. C.) Maximum Bus bar Temperature (Deg. C.) Maximum Enclosure Temperature (Deg. C.) Degree of Protection Bus bar Size for Phase Bus bar Size for Neutral No. of Runs : : : : : : : : : : : : : : : : : : Cubical Type 3PH ,3 Wire / 4 Wire 415V 50 Hz. 1000 50 50 85 70 IP: 52 & IP: 42 for ACB Incomer 1 x 1 x 125 x 10 MM 1 x 125 x 06 MM 1 1 125 10 750 1250 SMC support with ribbed construction

1.11

No. of times Interleaved Width of Bus Bar in mm Thickness of Bus Bar in mm Bus bar cross section for Neutral in Sq.mm Cross section of Bus bar Selected in Sq. mm Type of Insulator Basic Insulation Level: One Minute Power Frequency voltage Painting: a. Enclosure Interior & Exterior b. Bus bar Minimum Clearance: a. Phase to Phase b. Phase to Earth

1.12 1.13 1.14 1.15 a 1.16

2.5KV RMS

: : : : : : : :

Epoxy paint RAL-7032, Siemens Grey Heat Shrinkable Sleeved. 25 mm 20 mm IS: 8623 Construction IS : 5082 Bus bar IP: 54 for Indoor & IP: 55 for Outdoor 0.5mtr. (500mm)

1.17

1.18 1.19 1.20

Applicable Standard Degree of Protection Span Between 2 support

Page 1 of 12

1000 A MCC BUSBAR SIZING CALCULATION

PROJECT CLIENT CONSULTANT EPC CONTRACTOR Document ID 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT M/s. K.P.R. SUGAR MILL LTD M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. ISGEC HEAVY ENGINEERING LIMITED KR11-10302-CLC-001

Revision : 01
Date : 24-05-2012

No. of Sheet - 4

2 2.1

Bus duct Sizing Calculation for MCC Short Time Thermal Withstand Capability of Bus bar Minimum Cross Sectional Area of Busbar (A) In Sq. Inches Isc = Short Circuit Symmetrical Fault Current in KA T = Fault duration in Sec T1 = Initial Temperature of Busbar in Deg.C T2 = Final Temperature in Deg.C A = Cross sectional area of busbar in Sq.inches A in sq.mm = A x 645.16 = = = = = = ( Isc / T ) / {14 x 10 log [T1 +258)/(T2+258)] } 50 1 85 200 1.007851794 650.226 650.226 Sq.mm for pure aluminium. = 1250

2.2 2.2

Required cross sectional Area Actual Cross section of Bus bar Selected (As per Clause1.13) in Sq.mm Conclusion:

2.3 3 3.10

The required cross section 650.226 Sq.mm is less than actual cross section 1250 Sq.mm of the bus bar selected. Hence, the bus bar size chosen is safe for the envisaged system. Bus bar Selection for Continuous Current Rating : Bus bar Selected Open air rating of bus bar for 50 Deg. C rise over ambient in Amps. : : : : : : : : : : As per Clause1.11 1850 1 x 1850 1850 150 5500 x 800 x 2400 mm 800 x 400 mm 50 Deg. C 35 Deg. C MS Steel

3.11

No. of times Interleaved (As per Clause1.11) Overall Rating of Bus Bar in Amps. Phase spacing in mm. Enclosed Size in (W x D x H ) mm Bus bar Enclosed in (W x D ) mm Design Ambient Temperature Maximum allowable temp. rise Enclosure Material

3.12 3.13 3.14 3.15 3.16 3.17

Page 2 of 12

1000 A MCC BUSBAR SIZING CALCULATION

PROJECT CLIENT CONSULTANT EPC CONTRACTOR Document ID 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT M/s. K.P.R. SUGAR MILL LTD M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. ISGEC HEAVY ENGINEERING LIMITED KR11-10302-CLC-001

Revision : 01
Date : 24-05-2012

No. of Sheet - 4

3.18

De-rating / Up rating: a Ambient correction factor for 35 Deg. Rise b Enclosure correction factor corresponding to bus bar c Enclosure Correction factor Material (MS) d Proximity Effect Factor e Bus bar Configuration Factor g Combined Correction Factor De-rated Current rating of bus bar after applying Correction factor in Amps. = = = = = = = 0.9 0.87 0.9 0.95 1 0.67 1850 x 0.67

3.19

3.20 3.21 4 4.10 a b c

= 1238.51025 Rating of Panel required (As per Clause 1.5) = 1000 Conclusion : The de-rated Current rating 1238.51 amp of Panel selected is more than the required current rating 1000 amp of Bus duct Bus bar. Hence, the bus bar size chosen is safe for the envisaged system. Support Insulator Span Calculation During Short Circuit Fm = Peak Electromagnetic force along the centre = K x 16 x Isc x 10 / S line of busbar without enclosure Isc = Short Circuit Symmetrical Fault Current in KA S = Phase spacing in Meter K = Multiplying factor (s-a)/(a+b) corresponding to a that is 60 Fm (Nm / cm ) Fm ( Kg / cm ) = (Fm x 0.1019716) F = Force acting on top of the insulator Where, H = Cantilever Height of insulator in mm h = Distance between surface of insulator to centre of Bus bar in mm F Average span to be addopted in mm = = = = = = = = = = = = 50 0.250 0.904 0.4 (Reffering to curve K is 0.9) 14400.000 1468.391 Fm (H+h)/4H 38 75 1091.632813 Cantilever Strength of insulator / safety factor x F Sk / (SF x F ) 1600 2.5 586.278 OK

4.12 a b

4.13

a b

SK = Cantilever strength of insulator(Kg/cm) SF = Safety factor Length of Span of insulator in mm Adopted Span is Conclusion:

= = =

4.4

Average span of 586.278 mm is required but span adopted is 500 mm, hence it is safe for the system envisaged.

Page 3 of 12

1000 A MCC BUSBAR SIZING CALCULATION

PROJECT CLIENT CONSULTANT EPC CONTRACTOR Document ID 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT M/s. K.P.R. SUGAR MILL LTD M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. ISGEC HEAVY ENGINEERING LIMITED KR11-10302-CLC-001

Revision : 01
Date : 24-05-2012

No. of Sheet - 4

5 5.1 5.2 5.3 5.4

Temperature Rise Calculation Where, I1=Calculated Rating in Amps (After deration) As per Clause 3.19 I2 = Specified Rating in Amps as per clause 1.5 T1 = Max. Temp. Rise (in Deg.C) Specified T2 = Temp. Rise in Deg. C to be calculated as T2 = = = = = = Calculated Temperature is Conclusion : = 1238.51025 1000 35 ( I1 / I2 ) = ( T1 / T2 T1 / (I1 / I2 ) 24.64 OK
1.64 )0.61

5.5

The Calculated Temperature rise of bus bar is 24.64 Deg. C, which is within the design Specified Temp. 35 Deg. C and it is safe for the System envisaged.

Prepared By: Ganpat C

Checked By : Kamlakar D.

Approved By : A.B.H

Page 4 of 12

630 A MCC BUSBAR SIZING CALCULATION

PROJECT CLIENT CONSULTANT EPC CONTRACTOR Document ID 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT M/s. K.P.R. SUGAR MILL LTD M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. ISGEC HEAVY ENGINEERING LIMITED KR11-10302-CLC-001

Revision : 01
Date : 24-05-2012

No. of Sheet - 4

1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10

Input Data Type of Panel System Rated Voltage degree of Protection Panel Max. Current Rating in Amp (Design) Fault Current & Duration (KA RMS Symmetrical for 1 Sec.) Ambient Temperature (Deg. C.) Maximum Bus bar Temperature (Deg. C.) Maximum Enclosure Temperature (Deg. C.) Degree of Protection Bus bar Size for Phase Bus bar Size for Neutral No. of Runs : : : : : : : : : : : : : : : : : : Cubical Type 3PH ,3 Wire / 4 Wire 415V 50 Hz. 630 50 50 85 70 IP: 52 & IP: 42 for ACB Incomer 1 x 1 x 75 x 12 MM 1 x 75 x 06 MM 1 1 75 12 450 900 SMC support with ribbed construction

1.11

No. of times Interleaved Width of Bus Bar in mm Thickness of Bus Bar in mm Bus bar cross section for Neutral in Sq.mm Cross section of Bus bar Selected in Sq. mm Type of Insulator Basic Insulation Level: One Minute Power Frequency voltage Painting: a. Enclosure Interior & Exterior b. Bus bar Minimum Clearance: a. Phase to Phase b. Phase to Earth

1.12 1.13 1.14 1.15 a 1.16

2.5KV RMS

: : : : : : : :

Epoxy paint RAL-7032, Siemens Grey Heat Shrinkable Sleeved. 25 mm 20 mm IS: 8623 Construction IS : 5082 Bus bar IP: 54 for Indoor & IP: 55 for Outdoor 0.5mtr. (500mm)

1.17

1.18 1.19 1.20

Applicable Standard Degree of Protection Span Between 2 support

Page 5 of 12

630 A MCC BUSBAR SIZING CALCULATION

PROJECT CLIENT CONSULTANT EPC CONTRACTOR Document ID 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT M/s. K.P.R. SUGAR MILL LTD M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. ISGEC HEAVY ENGINEERING LIMITED KR11-10302-CLC-001

Revision : 01
Date : 24-05-2012

No. of Sheet - 4

2 2.1

Bus duct Sizing Calculation for MCC Short Time Thermal Withstand Capability of Bus bar Minimum Cross Sectional Area of Busbar (A) In Sq. Inches Isc = Short Circuit Symmetrical Fault Current in KA T = Fault duration in Sec T1 = Initial Temperature of Busbar in Deg.C T2 = Final Temperature in Deg.C A = Cross sectional area of busbar in Sq.inches A in sq.mm = A x 645.16 = = = = = = ( Isc / T ) / {14 x 10 log [T1 +258)/(T2+258)] } 50 1 85 200 1.007851794 650.226 650.226 Sq.mm for pure aluminium. = 900

2.2 2.2

Required cross sectional Area Actual Cross section of Bus bar Selected (As per Clause1.13) in Sq.mm Conclusion:

2.3 3 3.10

The required cross section 650.226 Sq.mm is less than actual cross section 900 Sq.mm of the bus bar selected. Hence, the bus bar size chosen is safe for the envisaged system. Bus bar Selection for Continuous Current Rating : Bus bar Selected Open air rating of bus bar for 50 Deg. C rise over ambient in Amps. : : : : : : : : : : As per Clause1.11 1350 1 x 1350 1350 150 7800 x 800 x 2400 mm 800 x 400 mm 50 Deg. C 35 Deg. C MS Steel

3.11

No. of times Interleaved (As per Clause1.11) Overall Rating of Bus Bar in Amps. Phase spacing in mm. Enclosed Size in (W x D x H ) mm Bus bar Enclosed in (W x D ) mm Design Ambient Temperature Maximum allowable temp. rise Enclosure Material

3.12 3.13 3.14 3.15 3.16 3.17

Page 6 of 12

630 A MCC BUSBAR SIZING CALCULATION

PROJECT CLIENT CONSULTANT EPC CONTRACTOR Document ID 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT M/s. K.P.R. SUGAR MILL LTD M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. ISGEC HEAVY ENGINEERING LIMITED KR11-10302-CLC-001

Revision : 01
Date : 24-05-2012

No. of Sheet - 4

3.18

De-rating / Up rating: a Ambient correction factor for 35 Deg. Rise b Enclosure correction factor corresponding to bus bar c Enclosure Correction factor Material (MS) d Proximity Effect Factor e Bus bar Configuration Factor g Combined Correction Factor De-rated Current rating of bus bar after applying Correction factor in Amps. = = = = = = = 0.9 0.87 0.9 0.95 1 0.67 1350 x 0.67

3.19

3.20 3.21 4 4.10 a b c

= 903.77775 Rating of Panel required (As per Clause 1.5) = 630 Conclusion : The de-rated Current rating 903.78 amp of Panel selected is more than the required current rating 630 amp of Bus duct Bus bar. Hence, the bus bar size chosen is safe for the envisaged system. Support Insulator Span Calculation During Short Circuit Fm = Peak Electromagnetic force along the centre = K x 16 x Isc x 10 / S line of busbar without enclosure Isc = Short Circuit Symmetrical Fault Current in KA S = Phase spacing in Meter K = Multiplying factor (s-a)/(a+b) corresponding to a that is 60 Fm (Nm / cm ) Fm ( Kg / cm ) = (Fm x 0.1019716) F = Force acting on top of the insulator Where, H = Cantilever Height of insulator in mm h = Distance between surface of insulator to centre of Bus bar in mm F Average span to be addopted in mm = = = = = = = = = = = = 50 0.250 0.904 0.4 (Reffering to curve K is 0.9) 14400.000 1468.391 Fm (H+h)/4H 38 75 1091.632813 Cantilever Strength of insulator / safety factor x F Sk / (SF x F ) 1600 2.5 586.278 OK

4.12 a b

4.13

a b

SK = Cantilever strength of insulator(Kg/cm) SF = Safety factor Length of Span of insulator in mm Adopted Span is Conclusion:

= = =

4.4

Average span of 586.278 mm is required but span adopted is 500 mm, hence it is safe for the system envisaged.

Page 7 of 12

630 A MCC BUSBAR SIZING CALCULATION

PROJECT CLIENT CONSULTANT EPC CONTRACTOR Document ID 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT M/s. K.P.R. SUGAR MILL LTD M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. ISGEC HEAVY ENGINEERING LIMITED KR11-10302-CLC-001

Revision : 01
Date : 24-05-2012

No. of Sheet - 4

5 5.1 5.2 5.3 5.4

Temperature Rise Calculation Where, I1=Calculated Rating in Amps (After deration) As per Clause 3.19 I2 = Specified Rating in Amps as per clause 1.5 T1 = Max. Temp. Rise (in Deg.C) Specified T2 = Temp. Rise in Deg. C to be calculated as T2 = = = = = = Calculated Temperature is Conclusion : = 903.77775 630 35 ( I1 / I2 ) = ( T1 / T2 T1 / (I1 / I2 ) 19.37 OK
1.64 )0.61

5.5

The Calculated Temperature rise of bus bar is 19.37 Deg. C, which is within the design Specified Temp. 35 Deg. C and it is safe for the System envisaged.

Prepared By: Ganpat C

Checked By : Kamlakar D.

Approved By : A.B.H

Page 8 of 12

800 A MCC BUSBAR SIZING CALCULATION

PROJECT CLIENT CONSULTANT EPC CONTRACTOR Document ID 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT M/s. K.P.R. SUGAR MILL LTD M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. ISGEC HEAVY ENGINEERING LIMITED KR11-10302-CLC-001

Revision : 01
Date : 24-05-2012

No. of Sheet - 4

1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10

Input Data Type of Panel System Rated Voltage degree of Protection Panel Max. Current Rating in Amp (Design) Fault Current & Duration (KA RMS Symmetrical for 1 Sec.) Ambient Temperature (Deg. C.) Maximum Bus bar Temperature (Deg. C.) Maximum Enclosure Temperature (Deg. C.) Degree of Protection Bus bar Size for Phase Bus bar Size for Neutral No. of Runs : : : : : : : : : : : : : : : : : : Cubical Type 3PH ,3 Wire / 4 Wire 415V 50 Hz. 800 50 50 85 70 IP: 52 & IP: 42 for ACB Incomer 1 x 1 x 100 x 10 MM 1 x 100 x 06 MM 1 1 100 10 600 1000 SMC support with ribbed construction

1.11

No. of times Interleaved Width of Bus Bar in mm Thickness of Bus Bar in mm Bus bar cross section for Neutral in Sq.mm Cross section of Bus bar Selected in Sq. mm Type of Insulator Basic Insulation Level: One Minute Power Frequency voltage Painting: a. Enclosure Interior & Exterior b. Bus bar Minimum Clearance: a. Phase to Phase b. Phase to Earth

1.12 1.13 1.14 1.15 a 1.16

2.5KV RMS

: : : : : : : :

Epoxy paint RAL-7032, Siemens Grey Heat Shrinkable Sleeved. 25 mm 20 mm IS: 8623 Construction IS : 5082 Bus bar IP: 54 for Indoor & IP: 55 for Outdoor 0.5mtr. (500mm)

1.17

1.18 1.19 1.20

Applicable Standard Degree of Protection Span Between 2 support

Page 9 of 12

800 A MCC BUSBAR SIZING CALCULATION

PROJECT CLIENT CONSULTANT EPC CONTRACTOR Document ID 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT M/s. K.P.R. SUGAR MILL LTD M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. ISGEC HEAVY ENGINEERING LIMITED KR11-10302-CLC-001

Revision : 01
Date : 24-05-2012

No. of Sheet - 4

2 2.1

Bus duct Sizing Calculation for MCC Short Time Thermal Withstand Capability of Bus bar Minimum Cross Sectional Area of Busbar (A) In Sq. Inches Isc = Short Circuit Symmetrical Fault Current in KA T = Fault duration in Sec T1 = Initial Temperature of Busbar in Deg.C T2 = Final Temperature in Deg.C A = Cross sectional area of busbar in Sq.inches A in sq.mm = A x 645.16 = = = = = = ( Isc / T ) / {14 x 10 log [T1 +258)/(T2+258)] } 50 1 85 200 1.007851794 650.226 650.226 Sq.mm for pure aluminium. = 1000

2.2 2.2

Required cross sectional Area Actual Cross section of Bus bar Selected (As per Clause1.13) in Sq.mm Conclusion:

2.3 3 3.10

The required cross section 650.226 Sq.mm is less than actual cross section 1000 Sq.mm of the bus bar selected. Hence, the bus bar size chosen is safe for the envisaged system. Bus bar Selection for Continuous Current Rating : Bus bar Selected Open air rating of bus bar for 50 Deg. C rise over ambient in Amps. : : : : : : : : : : As per Clause1.11 1500 1 x 1500 1500 150 4400 x 800 x 2400 mm 800 x 400 mm 50 Deg. C 35 Deg. C MS Steel

3.11

No. of times Interleaved (As per Clause1.11) Overall Rating of Bus Bar in Amps. Phase spacing in mm. Enclosed Size in (W x D x H ) mm Bus bar Enclosed in (W x D ) mm Design Ambient Temperature Maximum allowable temp. rise Enclosure Material

3.12 3.13 3.14 3.15 3.16 3.17

Page 10 of 12

800 A MCC BUSBAR SIZING CALCULATION

PROJECT CLIENT CONSULTANT EPC CONTRACTOR Document ID 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT M/s. K.P.R. SUGAR MILL LTD M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. ISGEC HEAVY ENGINEERING LIMITED KR11-10302-CLC-001

Revision : 01
Date : 24-05-2012

No. of Sheet - 4

3.18

De-rating / Up rating: a Ambient correction factor for 35 Deg. Rise b Enclosure correction factor corresponding to bus bar c Enclosure Correction factor Material (MS) d Proximity Effect Factor e Bus bar Configuration Factor g Combined Correction Factor De-rated Current rating of bus bar after applying Correction factor in Amps. = = = = = = = 0.9 0.87 0.9 0.95 1 0.67 1500 x 0.67

3.19

3.20 3.21 4 4.10 a b c

= 1004.1975 Rating of Panel required (As per Clause 1.5) = 800 Conclusion : The de-rated Current rating 1004.19 amp of Panel selected is more than the required current rating 800 amp of Bus duct Bus bar. Hence, the bus bar size chosen is safe for the envisaged system. Support Insulator Span Calculation During Short Circuit Fm = Peak Electromagnetic force along the centre = K x 16 x Isc x 10 / S line of busbar without enclosure Isc = Short Circuit Symmetrical Fault Current in KA S = Phase spacing in Meter K = Multiplying factor (s-a)/(a+b) corresponding to a that is 60 Fm (Nm / cm ) Fm ( Kg / cm ) = (Fm x 0.1019716) F = Force acting on top of the insulator Where, H = Cantilever Height of insulator in mm h = Distance between surface of insulator to centre of Bus bar in mm F Average span to be addopted in mm = = = = = = = = = = = = 50 0.250 0.904 0.4 (Reffering to curve K is 0.9) 14400.000 1468.391 Fm (H+h)/4H 38 75 1091.632813 Cantilever Strength of insulator / safety factor x F Sk / (SF x F ) 1600 2.5 586.278 OK

4.12 a b

4.13

a b

SK = Cantilever strength of insulator(Kg/cm) SF = Safety factor Length of Span of insulator in mm Adopted Span is Conclusion:

= = =

4.4

Average span of 586.278 mm is required but span adopted is 500 mm, hence it is safe for the system envisaged.

Page 11 of 12

800 A MCC BUSBAR SIZING CALCULATION

PROJECT CLIENT CONSULTANT EPC CONTRACTOR Document ID 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT M/s. K.P.R. SUGAR MILL LTD M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. ISGEC HEAVY ENGINEERING LIMITED KR11-10302-CLC-001

Revision : 01
Date : 24-05-2012

No. of Sheet - 4

5 5.1 5.2 5.3 5.4

Temperature Rise Calculation Where, I1=Calculated Rating in Amps (After deration) As per Clause 3.19 I2 = Specified Rating in Amps as per clause 1.5 T1 = Max. Temp. Rise (in Deg.C) Specified T2 = Temp. Rise in Deg. C to be calculated as T2 = = = = = = Calculated Temperature is Conclusion : = 1004.1975 800 35 ( I1 / I2 ) = ( T1 / T2 T1 / (I1 / I2 ) 24.11 OK
1.64 )0.61

5.5

The Calculated Temperature rise of bus bar is 24.11 Deg. C, which is within the design Specified Temp. 35 Deg. C and it is safe for the System envisaged.

Prepared By: Ganpat C

Checked By : Kamlakar D.

Approved By : A.B.H

Page 12 of 12