Bus Bar Design Calculations for 2500A Bus Duct

Project: Sennar Paper Boards Limited

Date : 07.09.11
Page: 1 of 8
Data Data Values Unit Formula or reference
GENERAL INFORMATION
Type of Bus Bar Arrangement Inter-Leaved
System Voltage 690.00 V
System Phases 3.00 nos
System Neutral 1.00 no
Bus Bar Configuration R-Y-B-N
Number of Phases in Bus Chamber (R-Y-B) 3.00 nos
Number of Neutrals in Bus Chamber (N) 1.00 no
Rated Current 2,886.70 A
R.M.S. Value of short circuit current 85.00 KA
Duration of short circuit Current 1.00 sec
Peak fault current 187.00 KA
Ambient Temp. 50.00 o
C
Temp. rise over specified Ambient temperature 45.00 o
C
Initial busbar temperature before fault 95.00 o
C
Final busbar temperature after SC fault 200.00 o
C
Bus Bar Material E91E Grade Aluminium Alloy
Cross Section Rectangular
Width 125.00 mm
Thickness 12.00 mm
No. Runs of Bus Bar per Phase 2.00 nos
No. Runs of Bus Bar per Neutral 1.00 no
Temperature Co-effficient of Copper 0.00039 Ohms/oC
Density 8.96 gm/cc

Thermal conductivity 0.54 cal/Sec/Sq.cm/cm/oC

Modules of Elasticity 7,000.00 kg/mm2

Busbar jointing with high tensile cadmium coated bolts 4.00 nos
Busbar Insulation PVC SLEEVE
Jointing bolt size M 10
Hole diameter on the Busbar 11.00 mm
Mimimum busbar to busbar
12.00 mm
Distance (of the same phase)=Same thickness of the Busbar
 Bus Bar Design Calculations for 2500A Bus Duct
Project: Sennar Paper Boards Limited
Date : 07.09.11
Page: 2 of 8
Data Data Values Unit Formula or reference
Phase to Phase clearance (Minimum) 25.00 mm
Phase to Neutral (Minimum) 19.00 mm
Make of Bus Bar Supports Powermat
Type: Phase& Neutral Finger
No.of Fingers per Phase 2.00 nos
No.of Fingers per Neutral 1.00 nos
Thickness of support Insulator 2.00 cm
Depth of Slot 1.50 cm
Busbar support material SMC
Specific Gravity 1.70 gm/cc
Glass Contents 0.25
Water absorption 0.002
Tensile Strength 700.00 kg/cm2
Compressive Strength 1,800.00 kg/cm2
Impact Strength 60.00 kg-cm/cm2
Flexible Strength 1,550.00 kgf/cm2
Dielectric Strength 12.00 KV/mm
Tracking Index 600.00 Volts
Flammability Self Extinguishing
Outside width of the enclosure 700.00 mm
Inside width of the enclosure 696.00 mm
Outside height of enclosure 400.00 mm
Inside height of enclosure 396.00 mm
Phase to Phase centre distance 146.00 mm
Phase to Phase clear distance 104.00 mm
Factor of safety for insulators 2.50
Tensile strength of busbar supports used 700.00 kg/cm2
Span between Bus Bar Supports 500.00 mm
 Bus Bar Design Calculations for 2500A Bus Duct
Project: Sennar Paper Boards Limited
Date : 07.09.11
Page: 3 of 8
Data Data Values Unit Formula or reference
SIZING CALCUALATION FOR BUS BAR
Ambient Temparature 50.00 o
C T1
Temparature Raise 45.00 o
C T2
Temparature Factor: K1 (T1/T2) 0.588
Cross sectional area of the all Busbars/
Enclosure Factor: K2
Cross sectional area of the enclosure
<1% = 0.95
K2 as per Tables 5% = 0.90
10% = 0.85
Sleeve Factor as per Indal Table 2 Black Paint=1.2
for Black paint: K3 PVC Sleeve=1.0
High Altitude Factor for installations upto 1000m sea level: K4
Spacing Phase-Phase 104.00 mm L
Thickness of Phase busbars 24.00 mm T
Proximity Factor L/T
3W=0.82
4W=0.89
Proximity Factor: K5 5W=0.95
6W=0.99
>6W=1.00
Busbar material factor: K6
Net Derating Factor: K K1 x K2 x K3 x K4 x K5 x K6
Current carrying capacity of Aluminium busbars for proposed
3,120.00 A
configuration as per INDAL tables

Continuous Current carrying capacity of Aluminium busbars for proposed Current rating x Net derating
configuration taking into consideration the Derating Factor factor

Factor of Safety in current carrying capacity

Hence the selected bus bar configuration of Inter-leaved with 2R x 125 mm x12 mm per phase and
Conclusion
1R x 125 mm x 12 mm for neutral is adequate to carry 2500 Amps current.
 Bus Bar Design Calculations for 2500A Bus Duct
Project: Sennar Paper Boards Limited
Date : 07.09.11
Page: 4 of 8
Data Data Values Unit Formula or reference
VERIFICATION OF BUSBAR TEMPRARATURE RAISE DURING SHORT CIRCUIT
Fault Current in KA 85.00 KA
Fault duration in Secconds (t) 1.00 sec
Ambient Temp. 50.00 o
C
Temp. rise over specified Ambient temperature 45.00 o
C
Initial busbar temperature before fault 95.00 o
C
Ultimate Temperature to which temperature raise to be limited during peak
200.00 o
C
short circuit
50,000xSq.rt (t) /
Minimum Cross Section Area (A) of Busbars required to limit the (2.17x10000xSq.rt(log((1+0.003
cm 2
temperature to 200oC 6(200-45))/(1+(0.0036(85-
45)))))
Cross Section of the selected bus bar per phase cm2

Our prposed cross section of bus bars is adequate to meet the above temperature raise
Conclusion
requirements

CALCULATION TO CHECK MECHANICAL WITHSTANDABILITY DUE TO STRESSES GENERATED DURING

PEAK SHORT CIRCUIT CURRENT:
Force between the main Conductors
F = 2.04 x Is2 x L x 10-2/S
as per Siemens Hand Boook
Peak impulse short circuit current in kA 187.00 KA Is
Busbar support distance span in cm 50.00 cm L
Conductor Spacing 10.40 cm S

The force exerted by peak fault current is to be whithstood by the busbar

supports used. The busbar supports under consideration is 210K with Two 4,200.00 Kg
Fingers of Powermat make having Ultimate Tensile Strength of 4200 Kgs..

Factor of Safety Strength of busbar support / force experienced due to peak short circuit fault current

Since the factor of Safety is more than 2.5, the selection of bus bar supports is capable of
Conclusion
withstanding the mechanical forces generated during peak short circuit.
 Bus Bar Design Calculations for 2500A Bus Duct
Project: Sennar Paper Boards Limited
Date : 07.09.11
Page: 5 of 8
Result
 Bus Bar Design Calculations for 2500A Bus Duct
Project: Sennar Paper Boards Limited
Date : 07.09.11
Page: 6 of 8
Result
 Bus Bar Design Calculations for 2500A Bus Duct
Project: Sennar Paper Boards Limited
Date : 07.09.11
Page: 7 of 8
Result

1.064
3.810%

0.940

1.000
1.000

4.333

0.890

0.940
0.837
3120.000

2610.39

0.90

Hence the selected bus bar configuration of Inter-leaved with 2R x 125 mm x12 mm per phase and
1R x 125 mm x 12 mm for neutral is adequate to carry 2500 Amps current.
 Bus Bar Design Calculations for 2500A Bus Duct
Project: Sennar Paper Boards Limited
Date : 07.09.11
Page: 8 of 8
Result

11.28

30.00

Our prposed cross section of bus bars is adequate to meet the above temperature raise
requirements

L WITHSTANDABILITY DUE TO STRESSES GENERATED DURING

3,429.65

1.225

Since the factor of Safety is more than 2.5, the selection of bus bar supports is capable of
withstanding the mechanical forces generated during peak short circuit.