October 1995

Process Industry Practices

Electrical

PIP ELSBD01
Design and Fabrication of Metal-Enclosed
Nonsegregated-Phase Bus Duct Assemblies
 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has been
prepared from the technical requirements in the existing standards of major industrial users,
contractors, or standards organizations. By harmonizing these technical requirements into a
single set of Practices, administrative, application, and engineering costs to both the purchaser
and the manufacturer should be reduced. While this Practice is expected to incorporate the
majority of requirements of most users, individual applications may involve requirements that
will be appended to and take precedence over this Practice. Determinations concerning fitness
for purpose and particular matters or application of the Practice to particular project or
engineering situations should not be made solely on information contained in these materials.
The use of trade names from time to time should not be viewed as an expression of preference
but rather recognized as normal usage in the trade. Other brands having the same
specifications are equally correct and may be substituted for those named. All practices or
guidelines are intended to be consistent with applicable laws and regulations including OSHA
requirements. To the extent these practices or guidelines should conflict with OSHA or other
applicable laws or regulations, such laws or regulations must be followed. Consult an
appropriate professional before applying or acting on any material contained in or suggested by
the Practice.

©Process Industry Practices (PIP), Construction Industry Institute, The

University of Texas at Austin, 3208 Red River Street, Suite 300, Austin,
Texas 78705. PIP member companies may copy this practice for their internal
use.

3pr96 Minor format changes.

2pr96 Minor format changes.
Not printed with state funds
 October 1995

Process Industry Practices

Electrical

PIP ELSBD01
Design and Fabrication of Metal-Enclosed
Nonsegregated-Phase Bus Duct Assemblies

Table of Contents

1. Introduction ..................................2 5. Fabrication ................................... 6

1.1 Purpose..............................................2 5.1 General.............................................. 6
1.2 Scope.................................................2 5.2 Painting.............................................. 6
5.3 Nameplate ......................................... 7
2. References....................................2 5.4 ID Tag................................................ 7
2.1 Process Industry Practices (PIP).........2 5.5 Shipping............................................. 7
2.2 Industry Codes and Standards............2
6. Inspection and Testing................ 7
3. General..........................................2
7. Documentation............................. 8
4. Design ...........................................3 7.1 Documentation Content...................... 8
4.1 Bus Bars.............................................3 7.2 Seller Drawing and Data
4.2 Grounding Considerations ..................4 Requirements..................................... 8
4.3 Enclosures..........................................4
4.4 Wall/Floor Penetrations ......................5
4.5 Equipment Connections......................5
4.6 Space Heaters....................................5

Process Industry Practices Page 1 of 8

PIP ELSBD01
Design and Fabrication of Metal-Enclosed
Nonsegregated-Phase Bus Duct Assemblies October 1995

1. Introduction

1.1 Purpose
The purpose of this Practice is to provide a specification for purchase including
design, fabrication, and testing of a metal enclosed Bus Duct for application in
continuous process industry.

1.2 Scope
This Practice covers requirements for design, fabrication, and inspection and testing of
metal-enclosed, self cooled, nonsegregated-phase bus duct assemblies for use on up to
and including 34.5 kV nominal voltage systems, suitable for indoor and outdoor
applications.

2. References

Applicable requirements in the latest edition (or the edition indicated) of the following industry
standards and Process Industry Practices shall be considered an integral part of this Practice.

2.1 Process Industry Practices (PIP)

− PIP ELSBD01D - Data Sheet For Design and Fabrication of Metal-

Enclosed Nonsegregated-Phase BusDuct Assemblies (completed for
application)
2.2 Industry Codes and Standards
• American Society for Testing and Materials (ASTM)

− ASTM D1535 - Standard Method for Specifying Color by The Munsell

System
• Institute of Electrical and Electronic Engineers (ANSI/IEEE)

– ANSI/IEEE C37.20.1 - Standard for Metal-Enclosed Low-Voltage Power

Circuit Breaker Switchgear
– ANSI/IEEE C37.20.2 - Standard for Metal-Clad and Station-Type Cubicle
Switchgear
– ANSI/IEEE C37.23 - Standard for Metal-Enclosed Bus and Calculating
Losses in Isolated-Phase Bus
• National Fire Protection Association (NFPA)

– NFPA 70 - National Electrical Code (NEC)

3. General

3.1 Bus duct assembly shall be nonsegregated-phase, totally enclosed and rigidly
constructed, and shall include all required transitions and hardware for termination to
supply and load equipment.

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 PIP ELSBD01
Design and Fabrication of Metal-Enclosed
October 1995 Nonsegregated-Phase Bus Duct Assemblies

3.2 Sandwich type constructed bus duct assemblies are not acceptable.
3.3 Any conflicts between the referenced documents shall be identified to the Buyer in
writing for resolution. In general, when resolving conflicts, the following order of
precedence shall apply:
• Bus Duct Layout Sketch
• Data Sheet ELSBD01D
• This Specification ELSBD01
• Referenced Standards

4. Design

4.1 Bus Bars

4.1.1 General
4.1.1.1 Rating of bus assembly shall conform to the Data Sheet.
4.1.1.2 Unless otherwise specified on the Data Sheet, bus bars shall be
made of copper.
4.1.1.3 Uninsulated bus bars shall be plated for corrosion protection.
4.1.1.4 Unless otherwise specified on the Data Sheet, all bus bar joints
shall be tin or silver plated.
4.1.1.5 Bus bar and joints shall be manufactured to remove sharp edges and
to minimize corona.
4.1.1.6 For operating voltages of 4.76 kV and higher, bus bar assembly
impulse withstand voltage shall be in accordance with
ANSI C 37.23 - 1987, Table 3B. For maximum operating voltages
of less than 4.76 kV, the impulse withstand voltage shall be a
minimum of 45 kV.
4.1.2 Bracing
Bus bar assembly including the bus bracing shall be capable of withstanding
mechanical and thermal effects, without damage or deformation, of the short
circuit withstand current as specified on the Data Sheet.
4.1.3 Insulation
4.1.3.1 Bus bars for over 1000-volts systems shall be insulated unless
specified otherwise on the Data Sheet.
4.1.3.2 Bus bar insulation shall be liquid dipped or fluidized bed epoxy.
Sleeve type insulating systems are not acceptable.
4.1.3.3 All insulated bus bar joints shall be covered with formed insulating
boots. Termination connections shall also have insulating boots
provided.

Process Industry Practices Page 3 of 8

PIP ELSBD01
Design and Fabrication of Metal-Enclosed
Nonsegregated-Phase Bus Duct Assemblies October 1995

4.1.3.4 Bus bar insulation and insulating supports shall be made of flame-
retardant, track-resistant, non-hygroscopic materials that meet the
same requirements of insulating materials covering buses as defined
in Section 7.8 of ANSI/IEEE C37.23-1987.
4.1.3.5 Stand-off insulators and bus bar supports for bus duct rated 5 kV
and higher shall be made of porcelain or cycloaliphatic epoxy
material unless specified otherwise on the Data Sheet.

4.2 Grounding Considerations

4.2.1 Unless specified otherwise on the Data Sheet, bus duct assemblies for 3-
phase, 4-wire solidly grounded systems shall have a full sized neutral bus
bar.
4.2.2 High resistance grounded systems shall have a #8 AWG neutral conductor
with an insulation rating equal to that of the bus bar insulation. Conductor
may be inside or outside of the bus duct. Conductor shall be supplied by the
Seller.
4.2.3 Bus duct enclosure shall have a plated copper grounding pad on each end.
4.2.4 Ground bus bar or conductor shall be made of copper.

4.3 Enclosures

4.3.1 General
4.3.1.1 Bus duct enclosures shall be non-ventilated.
4.3.1.2 Enclosures for bus duct located indoors shall be drip-proof.
4.3.1.3 Enclosures for bus duct located outdoors shall:
a. Be watertight and weatherproof.
b. Have a sloped top that prevents collection of water.
c. Have screened breather/drains or 3/16” drain holes at low
points along the bottom.
4.3.1.4 External fasteners on enclosures located outdoors shall be made
from series 300 stainless steel.
4.3.1.5 Enclosures shall have removable covers for access to bus bar
joints and other internal devices. Access openings in horizontal
sections shall be located on the bottom of the enclosure.
4.3.1.6 Access openings shall have removable covers with Neoprene
gaskets and captive fasteners.
4.3.1.7 Enclosure for bus assemblies with a current rating less than
2000 amps shall be made from No. 11 gauge steel as a
minimum. For bus duct with a current rating of 2000 amps or
greater, all or part of the enclosure shall be made from non-

Page 4 of 8 Process Industry Practices

 PIP ELSBD01
Design and Fabrication of Metal-Enclosed
October 1995 Nonsegregated-Phase Bus Duct Assemblies

magnetic metal to limit induced current losses and circulating

currents by breaking the magnetic path.

4.3.2 Supports
4.3.2.1 Seller shall determine:
a. Location and type of supports required for the bus duct
enclosure.
b. Forces produced at the support points by bus duct enclosure.
4.3.2.2 Buyer shall be responsible for the fabrication of the bus
assembly supports.

4.4 Wall/Floor Penetrations

4.4.1 There shall be a flame-retardant and vapor-resistant barrier at locations
where the bus duct penetrates interior and exterior walls/floors. Unless
otherwise specified on the Data Sheet, barrier shall have a flame rating of
30 minutes minimum.
4.4.2 Wall/floor openings shall have a metal frame with drilled flange connection
between the outside of the bus duct enclosure and the wall/floor. The metal
frame shall be provided by the bus duct Seller.

4.5 Equipment Connections

4.5.1 Seller shall be responsible for the design and coordination of the bus duct
connections to associated equipment. Seller shall request, with the quotation,
the data required to design the connections. Data shall be provided by the
Buyer.
4.5.2 Seller shall provide transition section, if required, and flexible connectors for
bus duct connection to other equipment.
4.5.3 Seller shall provide splice plates, neoprene gaskets, and hardware required
for connections.

4.6 Space Heaters

4.6.1 Bus duct assemblies located outdoors shall have space heaters. Bus duct
located indoors shall have space heaters only when specified on the Data
Sheet.
4.6.2 Space heaters shall:
a. Be rated for 240 volts and sized to prevent internal condensation when
operated at 120 volts.
b. Have a maximum sheath temperature of 200°C unless specified
otherwise on the Data Sheet.

Process Industry Practices Page 5 of 8

PIP ELSBD01
Design and Fabrication of Metal-Enclosed
Nonsegregated-Phase Bus Duct Assemblies October 1995

c. Be accessible and removable from outside the enclosure with the bus
bars energized.
d. Be mounted on standoff spacers.
e. Be designed to maintain a minimum temperature differential of 5°C
above minimum ambient indicated on Data Sheet.
4.6.3 Space heater shall be thermostatically controlled unless otherwise specified
on the Data Sheet. Thermostat shall be adjustable and easily accessible.
4.6.4 Space heater circuit shall be terminated on a terminal block in a junction box
located at the switchgear end of the bus duct. Junction box shall be provided
by the Seller.
4.6.5 Interconnection wiring shall be metal clad cable if located within the
assembly or rigid conduit and wire if located external to the assembly.

5. Fabrication

5.1 General
Bus bars shall be fabricated to align properly with the mating terminals on the
equipment. Flexible connectors shall be used to compensate for thermal expansion of
the bus and not for misalignment.

5.2 Painting
5.2.1 External and internal steel surfaces of bus duct enclosure shall be painted.
Finish color shall be light gray No 61 in accordance with ASTM D 1535-89
(Munsell Notation 8.3 G6 10/0.54).
5.2.2 Paint system for enclosures located outdoors shall conform to
ANSI/IEEE C37.20.2 - 1993 Section 5.2.8.
5.2.3 Paint system for bus duct enclosures located indoors shall conform to
ANSI/IEEE C37.23-1987 Section 7.1.
5.2.4 Surface preparation and painting application shall conform to the paint
Seller’s written instructions.
5.2.5 Bus duct assembly Seller shall provide certification that the paint system
shall conform with the following:
Top or finish coat shall:
a. Be free from craters, pinholes, holidays, embedded foreign matter, and
other visual defects.
b. Provide complete hiding, consistent coverage and thickness, and
uniform color.
5.2.6 Seller shall supply two 1-pint cans of paint for field touch-up.

Page 6 of 8 Process Industry Practices

 PIP ELSBD01
Design and Fabrication of Metal-Enclosed
October 1995 Nonsegregated-Phase Bus Duct Assemblies

5.3 Nameplate
5.3.1 Each bus duct assembly shall have a permanent nameplate.
5.3.2 Nameplates shall be:
a. Made of machine engraved laminated plastic, with black engraving on
white background.
b. Attached to the bus duct with stainless steel self-tapping screws.

5.3.3 Information on the nameplate shall include the following as a minimum:

a. Maximum voltage
b. Rated continuous current of phase and neutral bus (if provided)
c. Insulation (BIL) level
d. Frequency
e. Rated short-time current, if applicable
f. Rated short circuit withstand current
g. Temperature rise of buses and enclosure
h. Manufacturer’s name, date of manufacture, and identifying number

5.4 ID Tag
Provide an ID Tag made of laminated plastic with black figures on a white
background. The tag shall list the Equipment No., Purchase Order No., and Project
No. as specified on the Data Sheet.

5.5 Shipping
Splice plates, gaskets, hardware, and other loose equipment required to connect bus
duct to equipment shall be identified and shipped with the bus duct.

6. Inspection and Testing

6.1 In addition to the Seller’s standard tests, each bus duct assembly shall be tested in
accordance with standard production tests defined in ANSI/IEEE C37.23 - 1987,
Section 6, unless otherwise specified on the Data Sheet.
6.2 Insulating material for covering buses and connections shall be tested in accordance
with Section 7.8 of ANSI/IEEE C37.23-1987. Proof of successful testing shall be
provided to the purchaser as certified test results.
6.3 Seller shall give purchaser two weeks advance notice of date of final tests.
6.4 Purchaser reserves the right to inspect the bus duct and witness the tests at the factory,
if specified on the Data Sheet.

Process Industry Practices Page 7 of 8

PIP ELSBD01
Design and Fabrication of Metal-Enclosed
Nonsegregated-Phase Bus Duct Assemblies October 1995

7. Documentation

7.1 Documentation Content

Drawings shall have a space on the right hand bottom corner for purchaser’s title
block.

7.2 Seller Drawing and Data Requirements

A B C D DESCRIPTION

X X X Detailed Bill of Material

X X X X General layout of equipment, showing all dimensions, weights,
location and outline drawings showing the final assembled configuration.
X X X Connection wiring diagrams for all electrical equipment
X X X Single-line, 3-line, and control schematic diagrams

X Certified test reports

X(1) Installation, Operation and Maintenance Manual
X Final As-Built Drawings
X X Recommended priced spare parts list

A. Bidder shall furnish these documents with proposal.

B. Seller shall furnish these documents for Buyer's review and authorization to
proceed before fabrication.
C. Seller shall furnish these documents as part of the final certified document
submittal.
(1) Equipment should be shipped with one set of installation, operation, and
maintenance manuals.
D. Final as-built within 2 weeks following shipment.
Note: Seller to provide 1 reproducible set of drawings plus the specified
number of copies of all documentation and operating manuals as
indicated on the Data Sheet. Format for reproducible shall be CAD
convertible .dxf electronic format, unless the Seller specifies otherwise
in the proposal.

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