Evaluation, Design Estimation & Costing of Bus Ducts

Evaluation, Estimation & Costing of Bus ducts Project report/Technical paper
2009
Evaluation, Design
Estimation & Costing
of Bus ducts
Prepared by
Pankaj Kumar Rajput
©Pankaj Kumar Page 1 of 27

Table of Contents
Table of Contents ................................................................................................................................................ 1
1. Title of the Project ....................................................................................................................................... 3
2. Objectives of the study ................................................................................................................................ 3
3. Methodology used for carrying out the study ............................................................................................ 3
4. Statement of the Problem ........................................................................................................................... 3
5. Input data/Structure/Questionnaire ........................................................................................................... 3
6. Analysis/Solution/Description ..................................................................................................................... 4
A. Type of busbars: ...................................................................................................................................... 4
B. Busduct design & costing: ....................................................................................................................... 7
a) Introduction to busduct design ........................................................................................................... 7
b) Basic constructional details of air insulated non!segregated phase enclosed Busducts .................... 7
c) Basic design parameters: ..................................................................................................................... 8
d) Components of a busduct: .................................................................................................................. 8
e) Design calculation of busduct:............................................................................................................. 9
i. Aluminium bus bars ......................................................................................................................... 9
ii. MS sheet for enclosure.................................................................................................................. 13
iii. FRP sheet for support insulators ................................................................................................... 16
f) Other design validations: ................................................................................................................... 16
g) Calculation of weights of raw materials: ........................................................................................... 17
i. Aluminium bus bars ....................................................................................................................... 17
ii. MS sheet for enclosure.................................................................................................................. 17
iii. FRP sheet for support insulators ................................................................................................... 18
h) Calculation of cost of busduct: .......................................................................................................... 18
i) Cost model – MS Excel: ..................................................................................................................... 20
7. Final Results ............................................................................................................................................... 22
8. Conclusion ................................................................................................................................................. 22
9. Scope of Future Study ............................................................................................................................... 22
Appendix 1: Derating factors for busbar ........................................................................................................... 23
Appendix 2: Standard Aluminium busbar sizes and their Ampacity table ........................................................ 24
Appendix 3: Indoor busbars – Minimum clearances ......................................................................................... 25
Appendix 4: Modulus of Inertia between busbars ............................................................................................ 26
References: ........................................................................................................................................................ 27

Project Report
1. Title of the Project
Evaluation, design, estimation & costing of Bus ducts
2. Objectives of the study
! Study of types & design parameters of Busbars

! Study of cost components of Busducts
! Preparation of a cost module for Busducts for estimation of approximate cost
3. Methodology used for carrying out the study
! Study of various types of busbars from technical books & internet

! Selection of the type of Busduct for which design & cost approximation tool is to be developed
! Collection of preliminary & basic design data of standard Busduct from books & internet sites.
! Preparation of components breakdown structure of selected Busduct
! Perform design & cost calculation of selected busduct
! Development of cost module in MS Excel software
! Testing of the module by taking output for a selected rating of Busduct
! Validation of cost output by taking a feedback from any one manufacturer of bus duct
4. Statement of the Problem
! To minimize the errors in cost approximation by the project estimation engineers in estimating
the cost of the equipment i.e. bus duct in our case, during planning phase of the project.
! To improve the process of price negotiation by working out a target cost based on the cost of
components used in manufacturing of Busducts. Conventional way of negotiation is collecting
offers from the suppliers and negotiating on the basis of cost provided by the suppliers.
5. Input data/Structure/Questionnaire
! Find out the details of various types of Busbars & Busducts

! Prepare structured design evaluation of Busducts
! Study & list down the components of Busducts
! Get information & basic formula for weight & cost calculation of raw materials
! Prepare structured bill of material & cost of various components of Busducts
! Make a program in MS Excel to calculate the cost of Busduct by entering basic inputs
! Test the program and finalize

6. Analysis/Solution/Description
Conductors are required for distribution of power from Generators to switchgear and loads. The main
current carrying parts in an electrical system include:
! Busbars
! Connectors & clamps
! Power cables
! Live parts of the equipments
These parts carry normal load current continuously and are also subjected to high currents during faults.
The conductors are either provided with insulation or installed on insulators with adequate clearance &
creep age distances.
An aluminum or copper conductor supported by insulators that interconnects the loads and the
sources of electric power in an electric power system is known as Busbar. For higher current ratings,
generally more than 800A, the higher temperature rise & losses in cables makes the design & execution
difficult as it requires over!sizing of cables. The busducts (enclosed busbars) provide an economical &
technically superior solution.
A. Type of busbars:
1) Based on installation
a) Outdoor i.e. Open or enclosed busbars subjected to installation in open sky or outside of sub!
stations in open atmosphere
b) Indoor i.e. Open or enclosed busbars subjected to installation inside the sub!station of closed
atmosphere i.e. protected from rain, dust, vermin etc.
2) Based on type of conductor’s construction

a) Flexible i.e. ACSR (Aluminium Conductor Steel Reinforced) or AAC (All Aluminium Conductor)
conductors installed on insulators. These are generally used for outdoor installations. Flexible
copper links are also used to connect enclosed rigid busbars for inside or outside installations.
b) Rigid. These are in form of flats, channels or tubular pipes of Aluminium or Copper
3) Based on cooling media

a) Air insulated i.e. Open or metal enclosed busbars
b) Gas insulated i.e. Busbars enclosed in gas filled metal enclosure e.g. SF6 gas
c) Oil immersed i.e. Busbars enclosed in oil filled metal enclosure
4) Based on protective covering method

a) Open busbars i.e. Busbars which doesn’t have any protective cover
b) Enclosed busbars i.e. Busbars of rigid Aluminium or copper conductors, supported on
insulators, enclosed by sheet steel or aluminium sheets ducts.
The enclosed busbars are called Busducts. Bus duct is an assembly of bus conductors with
associated connections, joints and insulating supports confined within a metal enclosure with or
without inter!phase barriers.

5) Based on insulation between the phases, Busducts are of following types:

a) Non!segregated phase Busducts. The conductors of three phases are in a common metal
enclosure without any barrier between them. Busducts used for low voltage applications are
usually non!segregated phase busducts.
Pictorial cross sectional view of non!segregated busduct
b) Segregated phase Busducts. The conductors of three phases are in a common metal enclosure
with metal/insulated barriers (FRP) between them. This segregation minimizes the possibility
of a short circuit between the phases. Busducts used for medium voltages i.e. above 1.1 kV,
are usually non!segregated phase busducts.

Pictorial view of segregated phase busduct
c) Isolated phase Busducts. For very large currents in generating stations or substations, where it
is difficult to provide circuit protection, an Isolated Phase Busduct is used. Each phase of the
circuit is run in a separate grounded metal enclosure, hence the phase are Isolated. The only
fault possible is a phase!to!ground fault, since the enclosures are separated. This type of bus
can be rated up to 50,000 amperes and up to hundreds of kilovolts.
Low range – Typical 1 insulator High range – Typical 3 or 4 insulators

Pictorial view of isolated phase busduct

B. Busduct design & costing:

Our focus of cost estimation study is Busduct i.e. enclosed bus bars.
We choose air insulated non!segregated phase Busduct for our case study.
a) Introduction to busduct design

The dimensions of busbars are determined considering normal operating conditions i.e. rated
current. The system voltage determines the phase to phase & phase to earth distance and also
determines the height and shape of the supports to ensure adequate creep!age clearance (the
shortest distance between earthed end to the conductor, along the contour along external
surface of insulator).
Design validations are done to ensure that the busbar & supports are adequate to withstand the
mechanical & thermal effects due to short circuit currents. Design validations are also done to
ensure the temperature rise of conductors & enclosure is within safe limits.
We also have to check that the period of vibration to the busbars themselves is not resonant
with the system current frequency. During normal power frequency current flow, the conducting
parts and associated insulating & other mechanical parts experience mechanical oscillations. The
nature of such oscillations depends on operating frequency & the characteristics frequency of
the equipment. In case of resonance, the structural parts are likely to fail.
b) Basic constructional details of air insulated non!segregated phase enclosed Busducts

NSPB consists of enclosure in rectangular form with conductors in the form of flats/channels of
Aluminium/Copper material. These conductors are usually supported on FRP supports. Following
are the basic constructional details of an air insulated non!segregated phase busduct:
i. Bus conductor
The bus conductors shall be of Aluminium or 99%+ conductivity copper with silver!plated
joints. The bars shall be mounted on track resistant material and shall be insulated their
entire length with an epoxy coating or heat shrinkable PVC sleeves for 2400V service and
above. The insulation may also be provided for service voltage below 2400V, but it’s not
mandatory. Typical joints of conductor buses shall be insulated with removable boots and

jointed by double splice plates. A typical joint may use tape or heat shrink tubing to insulate
when insulation is required.
A 50x6 mm or other suitable size of Aluminium or bare copper conductor ground bus shall
be installed and bolted to metal enclosure to provide continuous electrical ground.
ii. Enclosure
The metal enclosures shall be made from suitable thickness (usually between 11!14 gauge)
Sheet steel, Aluminum or Stainless steel. Aluminium & Stainless steel being non!magnetic
materials results in low losses due to electromagnetic induction. Hence the enclosure size is
less for Aluminium & Stainless steel in comparison to MS sheets. MS sheet enclosures are
used up to current rating of 2500A and Aluminium or stainless steel sheet enclosures are in
practice for ratings more than 2500A. Galvanized Iron (GI) sheet enclosures can also be used
in place of MS enclosure particularly for outdoor application.
Outdoor enclosures shall be additionally provided with rain canopy for water ingress
protection. Enclosures shall be finished with baked!on polyester powder coat paint that
results in a uniform thickness and gloss!able to withstand harsh environments. Standard
color is ANSI!61 light gray, special colors shall also be used if required. All enclosures should
have removable covers secured with bolts for easy access to the joints for periodic
inspection. Flexible joints shall be supplied in all straight bus runs at intervals of
approximately 50 feet to allow for expansion when conductors are energized and carrying
rated current. Minimum two numbers of space heaters with thermostats shall be provided
to prevent moisture condensation and maintain cubicle temperature 5 "C above the
ambient. The busduct shall be provided with silica gel breathers, in all sections.
c) Basic design parameters:

Following are the basic design parameters of an air insulated non!segregated phase busduct:
! Conductor material e.g. Aluminium or Copper
! Conductor type e.g. Rectangular bar, channel or pipe
! Normal current rating e.g. 1200, 1600, 2000, 2500, 3200, 4000 Amps. Etc.
! Rated short circuit current e.g. 40kA for 1 Sec
! Rated voltage e.g. 415, 460, 3300, 6600, 11000, 22000, 33000 etc.
! Rated frequency e.g. 50 or 60 Hz
! Rated Basic Insulation Level (BIL) e.g. BIL for 11kV system is 12/28/75 kV, where
12kV : Highest system voltage
28kV : Power frequency withstand voltage
75kV : Impulse withstand voltage
! Permissible temperature rise of conductor & enclosure e.g. above 50"C ambient
Plain electrolytic copper : 35"C
Plain Aluminium : 35"C
Hotspot : 40"C
Enclosure : 20"C
! Enclosure material e.g. MS, SS, Aluminium sheet or GI
d) Components of a busduct:
Following are the components of an air insulated non!segregated phase bus ducts
! Conductor or Busbar
! Busbar insulation i.e. PVC sleeves or Epoxy paint
! Support Insulator e.g. FRP sheets, Post insulator – Epoxy or Porcelain

! Enclosure
! Silica gel breather & drain plugs
! Anti!condensing heater
! Marshalling box for heater & CT (if used)
! Misc hardware i.e. Nuts & bolts for jointing of bus bars & enclosure
! Flexible links for connecting busduct with equipment e.g. Tin coated copper flexible links
! Bends, disconnecting links (if required)
! Rain canopy for outdoor installation
! Wall frame assembly & support structure
e) Design calculation of busduct:
Design & calculate the cost of Busduct of following specifications:
3000A, 3Ø 415V, 50Hz, 40kA for 1 sec

Length – 15 Meters
Assumptions: We assume
! Conductor of Busbar is Aluminium

! PVC sleeves are used for busbar insulation
! Support insulators are FRP sheets
! Enclosure is of MS sheet of 2 mm thickness
! Single earth bus of 50x6 mm Al shall be provided
! 1 silica gel breather is used at every 6 meters length of busduct
! 1 anti condensation heater is used at every 6 meters length of busduct
! 1 marshalling box for heater connection is used at every 6 meters length of busduct
! There is no bend in the busduct
! Busduct is used inside, hence rain canopy is not required
Calculation of size of components:
i. Aluminium bus bars

Let’s
Current density of Aluminium for open busbar, " = 1.2 A/mm2
De!rating factor for Busbar, indoor, k* = 0.65
Density of Aluminium for bars = 2.7 gms/cm3
Adjusted current density of Al bus bar conductor, " = 1.2 x 0.65
= 0.78 A/mm2
"Required cross sectional area of busbar = (Rated current) / (Current density)
= 3000 / 0.78
= 3846 mm2
We choose busbar of 2nos of 200mm x 10mm size.
Hence actual cross sectional area of busbar = 2 x 200 x 10 = 4000 mm2
* Refer Appendix 1: Derating of busbars.

Design validation
We need to check if the busbars chosen

! Safely dissipates the generated heat (copper loss) and hence the conductor
temperature rise is within limit i.e. < conductor material softening temperature.
! Voltage drop, at receiving end, is within limits
! Mechanical strength Is more than the strain developed during short circuit
Temperature rise of conductor
Short circuit current = 40kA

Time duration = 1 sec
Cross section of busbar = 4000 mm2
Material of busbar = Aluminium
Formula:#
T = C * (Isc/a)2 * (1+!") * 10#2 * t
Where,
T = Final conductor temperature after fault, in "C
C = Material constant i.e. 0.54 for Copper, 1.17 for Aluminium
Isc = Short circuit Current, in Amps
a = Cross section area of conductor, in mm2
! = Temperature coefficient of resistivity at 20"C
0.00393 for Copper
0.04003 for Aluminium (EIE"M)
0.00364 for Aluminium alloy (E9IE – WP)
# = Initial conductor temperature before fault, in "C i.e. Ambient + permissible
temperature rise e.g. in our case it’s 50+35 = 85"C
t = Duration of fault, in sec
# Ref: “Electrical substation – Engineering & Practice” Handbook by S S Rao.
Calculation:
T = 1.17 * (40000/4000)2 * (1 + 0.00364 * 85) * 10"2 * 1

= 1.5 "C
Maximum temperature after flow of short circuit current = 85 + 1.5 = 86.5"C, which is
lower than the hot spot temperature 50+40=90"C and threshold temperature of 160"C,
above which Aluminium becomes soft and looses its mechanical strength.
If the temperature rise is not within limit, the busbar size needs to be increased.
Voltage drop
Rated current = 3000 A

Maximum permissible voltage drop < 2%

Formula:
The busbar reactance is not normally sufficiently large to affect the total reactance of a
power system and hence is not included in the calculations when establishing the short!
circuit currents and reactive volt drops within a power system. The voltage drop is
usually calculated from the circuit current & resistance of conductor.
Vd = IRac
= IRdc* k
= I * (! * L/a) * k
Where,
Vd = Voltage drop / phase
I = Rated current
Rdc = DC Resistance of conductor / phase
Rac = AC Resistance of conductor / phase
k = Correction factor for Skin & Proximity effect e.g. usually 1.2
" = Resistivity, in #!mm2/m
For Aluminium : 0.0287 ! at 0$C, 0.034 at 75$C
For Copper : 0.01724 ! at 0$C, 0.021 at 75$C
L = Conductor length, in m, i.e. 15 Meters in our case
a = Cross section area of conductor/phase, in mm2
Calculation:
Vd = I * (" * L/a) * 1.2

= 3000 * (0.034 * 15 / 4000) * 1.2
= 0.459 V
Voltage drop in %
Vd (%) = Vd * 100 / (VL / !3)

= 0.459 * 100 / (415 / !3)
= 0.19 %
The voltage drop is less than maximum permissible voltage drop i.e. 2%.
Hence the size of busbar conductor is safe.
Mechanical strength of busbar
The force occurs at the peak of first major loop of short circuit current. The force
between main conductors on a span (distance between two insulating supports) length
of busbar can be found out as below:
Formula:#
F = 2.04 * (idyn)2 * (D / r) * 10"2
Where,
F = Force between conductors, in Kgf
idyn = Peak value of short circuit current per conductor, in kA
idyn = 2.5 times of short circuit withstand current, for 50 Hz system
idyn per conductor = idyn / Number of conductors per phase
D = Span between insulators support, in cm

We consider 1 meter span i.e. 100 cm
r = Distance between neighboring conductors (Phases), in cm
# Ref: “Electrical substation – Engineering & Practice” Handbook by S S Rao.
Calculation:
Force between conductors, F = 2.04 x (40 x 2.5/2)2 x (100 / 17) x 10!2

= 300 Kg
= 294.2 daN *
* 1 daN (decaNewton) = 1.01972 Kg
The strain developed in busbar, due to bending moment by force occurred during short
circuit, can be found as below:
Formula:
! = (F * L / 12) * [1 / (I / V)]
Where,
F = Force between conductors, in daN
L = Span between insulators support, in cm
We have consider 1 meter span i.e. 100 cm
I/V = Modulus of Inertia, in cm3
Modulus of Inertia can be calculated as below (refer Appendix 4 for details):

I/v = 2 * [{(b * a3) / 12} + S * d2] / (1.5 * a)

= 2 x [{(200 x 103) / 12} + (200 x 10) x 102] / (1.5 x 10)
= 433333 / 15 mm3
= 28.89 cm3
Calculation:
Strain ! = (F * L / 12) * [1 / (I / V)]

= (294.2 x 100 / 12) x (1/28.89) daN/cm2
= 84.86 daN/cm2
The maximum fibre strain for Aluminium is 1056 daN/cm.
As the strain developed during short circuit is less than the maximum permissible strain,
the considered busbar size is safe.
ii. MS sheet for enclosure
As per IS 5578 & 11353,

Minimum gap required between Phases, f = 19 mm
Minimum gap required between Phase & Earth (Enclosure), g = 16 mm
We consider,
Minimum gap required between Phases, f = 25 mm
Minimum gap required between Phase & Earth (Enclosure), g = 20 mm
From calculations in (i), Busbar width, a = 200 mm & thickness, b = 10 mm
Minimum required width of enclosure, W = 2 x (t + g + d + e)

= 2 x [t + g + (f + 3b) + 1.5 b]
= 2 x (t + g + f + 4.5b)
= 2 x (2 + 20 + 25 + 4.5 x 10)
= 184 mm
Minimum required height of enclosure, H = 2 x (t + j + h) + (a! 2c)

= 2 x (2 + 25 + 100) + 200 – 2 x 20
= 414 mm
Considering dissipation of heat generated, supporting systems, rectangular shape etc.,

we take the dimensions as below:
Width of enclosure, W = 600 mm

Height of enclosure, H = 450 mm
Design validation
We need to check if the temperature rise of enclosure chosen is within the limit i.e. its
surface area is sufficient to dissipate the generated heat during normal situations.
Temperature rise of enclosure
Maximum rated current = 3000 A

We will first calculate the heat/copper losses occurred in conductor and then the
temperature rise of enclosure due to this heat. The walls of the enclosure dissipate the
heat by both radiation & convection.
Formula – Copper/heat loss generated:
Pc = I2Rac
= (! * a)2 * (" * L / a) * 1.2
= !2 * " * L * a * 1.2
Pi = Pc * 15% = 0.15 * Pc
P = 3 * (Pc + Pi)
= 3 * (Pc + 0.15Pc)
= 3.45 Pc
Where,
Pc = Copper loss in conductor / phase, in Watt
Pi = Stray losses in enclosure due to one phase, in Watt
I = Rated current, in Amps
R = Resistance of conductor, in Ohm
" = Current density, in A/mm2
# = Resistivity, in $!m
For Aluminium : 0.0287 x 10!6 ! at 0%C, 0.034 x 10!6 at 75%C
For Copper : 0.01724 x 10!6 ! at 0%C, 0.021 x 10!6 at 75%C
L = Conductor length, in m
a = Cross section area of conductor/phase, in mm2

Formula – Heat dissipation / Temperature rise:#
T = P / (! * St)
St = P / (! * T)
Where,
T = Temperature rise of enclosure from ambient in !C e.g. 20!C
P = Losses in bus conductor & enclosure, in Watt
! = Specific heat dissipation in Watt/m2
12.5 W/m2 for naturally cooled MS surface. 6.0 W/m2 by Radiation & 6.5
W/m2 by convection.
20 W/m2 for forced cooled surface
St = Heat dissipating surface area
# Ref: “Electrical machine design” Handbook by AK Sawney & Chakrabarti.
Calculation:
Copper loss per unit length/phase, Pc = "2 * # * L * a * 1.2

= (0.78)2 * 0.034 * 10$6 * 103 * 1000 *
4000 * 1.2
= 99.3 Watt
Total loss per unit length of conductors, P = 3.45 * Pc

= 342.5 Watt
Surface required for dissipation of heat loss, St = P / (! * T)

= 342.5 / (12.5 * 20)
= 1.37 m2
Actual heat dissipating area of enclosure = 2 * (Length + Width) * Height

= 2 *(1000 + 600) * 450
= 1,440,000 mm2
= 1.44 m2
As the heat dissipation surface area of considered enclosure is more than required area,
the temperature rise will be less than specified. Hence the size of enclosure is adequate.
The busbar arrangement can be as below:
W = 2 x (t + g + f + 4.5b)
Let,
g = f
" W = 2 x (2 + 2 x g + 4.5 x 10)

600 = 4g + 49
g = 137.75 mm
f = 137.75 mm
e = 1.5b = 15 mm
d = f + 3b = 137.75 + 3 x 10 = 167.75 mm

iii. FRP sheet for support insulators
Number of Busbar/Phase = 2 numbers 200x10 mm
!Busbar support size (L x B x H), in mm = (Width of enclosure ! 2 x 5 mm) x

Available standard width x standard thickness of FRP sheet
= (600 ! 10) x 200 x 8
= 590 x 200 x 8
Design validation
We need to check if the FRP sheet insulator chosen withstand the electrodynamics
forces of busbar during flow of short circuit currents.
We have already found out the force between main conductors due to short circuit:
Force between conductors, F = 300 Kg/m
Force acting on FRP insulator, F1 = F x Span

= 300 Kg/m x 1 m
= 300 Kgs
Area of contact between busbar & FRP plate is Groove depth x Thickness x No of
supports
Now,
Groove depth = 20 mm
Thickness = 8 mm
No of supports = 2
Area of contact between busbar & FRP plate = 20 x 8 x 2

= 320 mm2
Shear strength of standard FRP plate = 6.12 Kg/mm2
Shear strength of considered FRP plate = 6.12 Kg/mm2 x 320 mm

= 1958.4 Kg
Shear strength of the considered FRP plate i.e. 1958 Kg, is more than force on it i.e. 300
Kg. Hence it is safe.
f) Other design validations:
We also have to check that the period of vibration to the busbars themselves is not resonant
with the system current frequency.
The natural frequency of horizontal busbar, fixed at both ends, can be found from below
formula (referred from www.copperinfo.co.uk\busbars)
fn = 18.04 / " "

Where,
fn = Natural frequency of busbar, Hz
! = Maximum deflection, mm
! = 5w * L4 / (384 * E * I)
Where,
w = Weight per unit length of busbar, N/mm (Aluminium " 2.7 x 10"3 N/mm)
L = Busbar length between supports, mm = 1000 mm
E = Modulus of elasticity (Aluminium " 71 x 103 N/mm2)
I = Moment of inertia of busbar section, mm4
= 2 * [{(b * a3) / 12} + S * d2]
= 433333 mm4
! = 5 x (2 x 2.7 x 10"3) x (1000)4 / (384 x 71 x 103 x 433333)

= 2.286 x 10"3 mm
! fn = 18.04 / " (2.286 x 10"3)

= 377 Hz
The frequency of current flowing in busbar is 50 Hz. For harmonic currents, it will be in multiple
of fundamental frequency 50Hz. The busbar natural frequency is 377 Hz which is far away than
the normal frequency of current. Hence the busbar chosen is safe.
g) Calculation of weights of raw materials:
i. Aluminium bus bars

Cross sectional area of busbar/Phase = 2 x 200 x 10 = 4000 mm2
Volume of unit length (1 meter) of busbar/phase = 4000 mm2 x 1000 mm
= 4000 Cm3
Weight of unit length of busbar for all 3 phases = 3 x Volume x Density
= 3 x 4000 x 2.7
= 32.4 Kgs
Weight of Earthing bus for unit length = 1 x 50 x 6 x 2.7
= 0.81 Kgs
Total weight of aluminium busbars for unit length = 32.4 + 0.81 = 33.21 Kgs
Considering wastage of 5%, total weight of busbars # 35 Kgs/m
ii. MS sheet for enclosure

Size of enclosure,
Width of enclosure, W = 600 mm
Height of enclosure, H = 450 mm
Thickness of sheet, t = 2 mm
Cross sectional area of enclosure = 2 t * (W + H + 2t)

= 2 * 2 * (600 + 450 + 2 * 2)
= 4216 mm2
Volume of enclosure per unit length ( 1 meter) = 4216 * 1000 mm3

= 4216 cm3
Weight of enclosure, per unit length = Volume * Density
= 4216 cm3 * 7.81 gms/cm3
= 32.9 Kgs
Considering wastage of 5%, weight of enclosure ! 35 Kgs/m
iii. FRP sheet for support insulators

Size of FRP support insulator,
Width of support insulator, w = 600 – 10 = 590 mm
Height of support insulator, j = 100 mm
Thickness of sheet, t = 8 mm
Number of insulators per unit length = 2
Cross sectional area of FRP sheet =wxj

= 590 x 100
Volume of one FRP insulator sheet = 59000 mm2 x 8 mm
= 472 cm3
Weight of FRP insulator sheet per unit length = 2 x Volume x Density
= 2 x 472 x 1.799 gms
= 1.699 Kg
Considering wastage, total weight of FRP sheet ! 1.8 Kg/m
h) Calculation of cost of busduct:
Cost of busduct consists of
! Raw material cost

! Other components cost i.e. heater, thermostat, silica gel breather etc.
! Jointing hardware cost i.e. nuts, bolts washer etc.
! Overheads i.e. manufacturing expenses
! Manufacturer’s Profit
Let,
Rate of Aluminium + busbar preparation work = 145 Rs/Kg
Rate of MS sheet + fabrication + painting = 75 Rs/Kg
Rate of FRP sheet + its preparation etc. = 500 Rs/Kg
Rate of one anti"condensing heater + thermostat = 2000 Rs/set
Rate of marshalling box (JB) for heater connection = 1500 Rs/pc
Rate of Silica gel breather assembly = 1500 Rs/pc
Misc hardware cost = 10% of basic material cost
Manufacturing overheads + Labour charges = 10% of total material cost
Manufacturer’s Profit = 15% of total cost

i. Cost of raw materials
Cost of raw material = Length of busduct * Cost of raw

material/meter
Cost of raw material per meter = Weight * rate
Busbar cost – Rs/meter = 35 Kg x 145 Rs/Kg

= 5,075 /!
Enclosure cost – Rs/meter = 35 Kg x 75 Rs/Kg

= 2,625 /!
FRP insulator sheet cost – Rs/meter = 1.8 Kg x 500 Rs/Kg

= 900 /!
Cost of raw material, Rs/meter = 5,075 + 2,625 + 900

= 8,600 /!
Cost of raw material for 15 meters length of busduct, A ! Rs = 15 * 8,600

= 129,000 /!
ii. Cost of miscellaneous hardware & overheads
Cost of misc hardware @ 10% of cost of raw mat., B = 12,900 /!
Material cost, C = A + B = 141,900 /!
Cost of overheads @ 10% of material cost, D = 14,190 /!
Total material cost, E = C + D = 156,090 /!
iii. Cost of other components
Required number of heater + thermostat = 15 / 6 = 2

Required number of JB for heaters connection = 15 / 6 = 2
Required number of Silicagel breather = 15 / 6 = 2
Cost of above components, F = 2 x (2,000 + 1,500 + 1,500)

= 10,000 /!
iv. Manufacturer’s profit, G = 15% of (E + F)

= 24,913 /!
v. Total cost of Busduct of 15 meters length = E + F +G

= 191,003 /!
" 192,000 /!

i) Cost model – MS Excel:
Bus Ducts - Cost Model

Inputs
Busbar material Aluminium
Enclosure material Sheet steel
Rate of Aluminium 110 Rs/Kg
Rate of Copper 200 Rs/Kg
Rate of steel HR Sheets for Enclosure 30 Rs/Kg
Rate of FRP sheets for support insulators 500 Rs/Kg
Current rating Amp 3000 Amp
TPN or TP 3
Enclosure width 600 mm
Enclosure height 450 mm
Enclosure sheet thickness 2 mm
FRP sheet insulator width 590 mm
FRP sheet insulator height 100 mm
FRP sheet insulator thickness 8 mm
Busbar details
Width 200 mm
Thickness 10 mm
No. of Runs ( Qty / Ph ) 2
Earthbus Width 50 mm
Earthbus Thickness 6 mm
No. of earthbus runs 1
Current density of Al busbar 0.77 Amp/mm^2
Current density of Cu busbar 1.2 Amp/mm^2
Wastage in busbar 5.0%
Wastage in enclosure 5.0%
Misc hardware cost 10.0%
Labour + Overheads 10.0%
Profit 15.0%
Density of Aluminium 2.7 Gms/Cm3
Density of Copper 8.89 Gms/Cm3
Density of Sheet steel 7.81 Gms/Cm3

Outputs
Actual current rating of busbar 3,080 Amps
Current density of busbar material 0.77 Gms/Cm3
Density of busbar material 2.70 Gms/Cm3
Density of enclosure material 7.81 Gms/Cm3
Rate of busbar material including fabrication 145.00 Rs/Kg
Rate of enclosure material including fabrication, painting 75.00 Rs/Kg
Busbar X-section mm^2 12,300 mm2

Weight of busbar per m 34.87 Kg/m
Cost of busbar per m 5,056 Rs/m
Enclosure weight per m 34.6 Kg/m
Cost of enclosure (inclussive painting) per m 2,593 Rs/m
Insulator Plate Wt 0.89 Kg/m
Cost of Insulator plates per m 892 Rs/m
Misc hardware cost i.e. Nuts, bolts, gaskets etc 854 Rs/m
Total material cost 9,395 Rs/m
Labour cost and overheads 939 Rs/m
Total manufacturing cost 10,334 Rs/m
Profit 1,550 Rs/m
Indicative price per meter length 11,885 Rs/m

7. Final Results
! Various types of bus ducts were studied
! 3 phase, 415V, 50Hz, 3000A indoor non!segregated phase busduct was designed and the design
parameters were validated by various calculation methodologies
! Detailed costing was done for above busduct
! Cost module for above bus duct was made in MS Excel software and validated by collecting an
actual offer from one manufacturer.
8. Conclusion
! The busduct design details, given in this project report, can be referred by the practicing
design/project engineers
! This module can be used for cost approximation of indoor type non!segregated phase LV & MV
bus ducts up to 4000A rating
! This is very handy and elaborative design & cost approximation module for bus duct
9. Scope of Future Study
Similar design & cost module can me developed for
! Segregated phase bus ducts
! Isolated phase bus ducts
!!!

Appendix 1: Derating factors for busbar
Derating factor for bus bar, k = k1 * k2 * k3 * k4 * k5 * k6
Where,
! Coefficient k1 is a function of the number of bar strips per phase for:
For 1 bar, k1 = 1
2 or 3 bars, see table below:
e/a 0.05 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20
k1 for 2 bars 1.63 1.73 1.76 1.80 1.83 1.85 1.87 1.89 1.91
k1 for 2 bars 2.40 2.45 2.50 2.55 2.60 2.63 2.65 2.68 2.70
! Coefficient k2 is a function of surface condition of the busbars:

Bare: k2 = 1
Painted: k2 = 1.15
! Coefficient k3 is a function of the position of the bars:

Edge!mounted bars: k3 = 1
1 bar base!mounted: k3 = 0.95
Several base!mounted bars: k3 = 0.75
! Coefficient k4 is a function of the place where the bars are installed:

Calm indoor atmosphere: k4 = 1
Calm outdoor atmosphere: k4 = 1.2
Bars in non!ventilated ducting: k4 = 0.80
! Coefficient k5 is a function of the artificial ventilation:

Without artificial ventilation: k5 = 1
With artificial ventilation: k5 > 1
! Coefficient k6 is a function of the type of current:
For alternating current of frequency " 60 Hz, k6 is a function of the number of bars n per phase and
of their spacing.
The value of k6 for spacing equal to the thickness of the bars:

n 1 2 3
k6 1 1 0.98

Appendix 2: Standard Aluminium busbar sizes and their Ampacity table
Aluminum Bus Bar Amperes for 6101!T61 Alloy 57% IACS Conductivity Chart Below
Bar Sizes 1 Bar 2 Bars 3 Bars 4 Bars
(Inches) DC 60 Hz AC DC 60 Hz AC DC 60 Hz AC DC 60 Hz AC
1/4 x 1 308 308 607 601 605 887 1203 1168

1/4 x 1 1/2 430 429 833 817 1235 1194 1637 1561
1/4 x 2 549 545 1051 1021 1552 1480 2053 1915
1/4 x 3 780 768 1472 1410 2162 2000 2851 2530
1/4 x 4 1005 980 1878 1760 2749 2462 3619 3081
1/4 x 5 1225 1184 2275 2092 3321 2905 4365 3625
1/4 x 6 1443 1381 2665 2413 3881 3338 5095 4146
1/4 x 7 1870 1760 3427 3034 4974 4183 6517 5152
3/8 x 2 691 678 1340 1278 1989 1831 2638 2332
3/8 x 3 974 941 1857 1709 2739 2384 3620 2946
3/8 x 4 1249 1191 2356 2099 3460 2893 4563 3574
3/8 x 5 1519 1429 2842 2483 4162 3387 5479 4178
3/8 x 6 1785 1657 3320 2847 4848 3857 6375 4765
3/8 x 8 2308 2098 4253 3569 6188 4774 8119 5875
3/8 x 10 3822 2534 5165 4289 7493 5632 9817 6941
1/2 x 3 1145 1074 2205 1991 3265 2742 4324 3297
1/2 x 4 1462 1369 2782 2416 4100 3264 5417 3940
1/2 x 5 1774 1634 3345 2828 4912 3778 6477 4580
1/2 x 6 2081 1892 3897 3230 5706 4284 7514 5210
1/2 x 8 2685 2393 4975 4014 7255 5276 9531 6246
1/2 x 10 3278 2880 6209 4779 8763 6256 1149 7579
Note:
i. Ratings are based on 30°C rise over 40°C ambient in still but confined air (e=0.35), corresponding to usual
indoor temperature.
ii. Space between bars is assumed equal bar thickness.
iii. For AC phase spacing’s less than 18 inches an allowance for proximity effect must be made.

Appendix 3: Indoor busbars – Minimum clearances
Table 3.1 ! Indoor busbars : Open or enclosed ! Clearances for

voltages up to 33kV
Rated Minimum clearance to Minimum clearance

voltage Earth between Phases
rms Open Enclosed Open Enclosed
kV mm mm mm mm
0.415 19 16 26 19
0.6 26 19 32 19
3.3 51 51 51 51
11 77 77 127 127
15 102 102 165 165
22 140 140 242 242
33 223 223 356 356
Table 3.2 ! Indoor busbars : Open or enclosed ! Creep age distances
Rated voltage Minimum clearance to Earth
rms Phase to Earth Phase to Phase

kV cm cm
6.6 15 17.5
11 17.5 30
22 25 38
33 33 45
45 42 53
66 63 77
110 106 132
132 125 156
220 178 225
400 354 400

Appendix 4: Modulus of Inertia between busbars
! Modulus of inertia – One bar per phase
Moment of Inertia, I = (b * a3) / 12
Modulus of Inertia, I/v = [(b * a3) / 12] / (a / 2)

= (b * a2) / 6
! Modulus of inertia – Two bars per phase
Moment of Inertia, I = 2 * [{(b * a3) / 12} + S * d2]
Modulus of Inertia, I/v = 2 * [{(b * a3) / 12} + S * d2] / (1.5 * a)
Where, S = Busbar cross section of one bar (in cm2)
Standard table for cross section area S, linear mass m, moment of inertia I & modulus of inertia I/V

References:
1. “Electrical substation – Engineering & Practice” Handbook by S S Rao
2. “Electrical machine design” Handbook by AK Sawney & Chakrabarti
3. Website: http://www.copperinfo.co.uk/busbars
4. Website: http://en.wikipedia.org/wiki/Density
5. Website: http://www.fiberbond.com/docs/FRPdesign.pdf
6. Siemens, BCH & Schneider busduct catalogues

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Evaluation, Estimation & Costing of Bus ducts Project report/Technical paper

©Pankaj Kumar Page 1 of 27

©Pankaj Kumar Page 2 of 27

Evaluation, design, estimation & costing of Bus ducts

2. Objectives of the study

! Study of types & design parameters of Busbars

3. Methodology used for carrying out the study

! Study of various types of busbars from technical books & internet

4. Statement of the Problem

! Find out the details of various types of Busbars & Busducts

©Pankaj Kumar Page 3 of 27

2) Based on type of conductor’s construction

3) Based on cooling media

4) Based on protective covering method

©Pankaj Kumar Page 4 of 27

5) Based on insulation between the phases, Busducts are of following types:

Pictorial cross sectional view of non!segregated busduct

©Pankaj Kumar Page 5 of 27

Pictorial view of segregated phase busduct

Low range – Typical 1 insulator High range – Typical 3 or 4 insulators

©Pankaj Kumar Page 6 of 27

B. Busduct design & costing:

a) Introduction to busduct design

b) Basic constructional details of air insulated non!segregated phase enclosed Busducts

©Pankaj Kumar Page 7 of 27

c) Basic design parameters:

! Support Insulator e.g. FRP sheets, Post insulator – Epoxy or Porcelain

e) Design calculation of busduct:

Design & calculate the cost of Busduct of following specifications:

3000A, 3Ø 415V, 50Hz, 40kA for 1 sec

! Conductor of Busbar is Aluminium

Calculation of size of components:

i. Aluminium bus bars

* Refer Appendix 1: Derating of busbars.

We need to check if the busbars chosen

Temperature rise of conductor

Short circuit current = 40kA

T = C * (Isc/a)2 * (1+!") * 10#2 * t

# Ref: “Electrical substation – Engineering & Practice” Handbook by S S Rao.

T = 1.17 * (40000/4000)2 * (1 + 0.00364 * 85) * 10"2 * 1

Rated current = 3000 A

©Pankaj Kumar Page 10 of 27

Vd = I * (" * L/a) * 1.2

Vd (%) = Vd * 100 / (VL / !3)

Mechanical strength of busbar

F = 2.04 * (idyn)2 * (D / r) * 10"2

D = Span between insulators support, in cm

# Ref: “Electrical substation – Engineering & Practice” Handbook by S S Rao.

Force between conductors, F = 2.04 x (40 x 2.5/2)2 x (100 / 17) x 10!2

Modulus of Inertia can be calculated as below (refer Appendix 4 for details):

©Pankaj Kumar Page 12 of 27

I/v = 2 * [{(b * a3) / 12} + S * d2] / (1.5 * a)

Strain ! = (F * L / 12) * [1 / (I / V)]

The maximum fibre strain for Aluminium is 1056 daN/cm.

ii. MS sheet for enclosure

As per IS 5578 & 11353,

From calculations in (i), Busbar width, a = 200 mm & thickness, b = 10 mm

Minimum required width of enclosure, W = 2 x (t + g + d + e)

Minimum required height of enclosure, H = 2 x (t + j + h) + (a! 2c)

Considering dissipation of heat generated, supporting systems, rectangular shape etc.,

Width of enclosure, W = 600 mm

Temperature rise of enclosure

Maximum rated current = 3000 A

Formula – Copper/heat loss generated:

Evaluation, Design Estimation & Costing of Bus Ducts

Evaluation, Design Estimation & Costing of Bus Ducts