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NEDAL ALUMINIUM NEDAL BUSBAR’S STRONG POINTS Technically perfected CALCULATION OF SPECIFICATIONS
The excellent quality of Nedal busbars is the result of many ACCORDING TO KEMA PROVISIONS
The natural qualities of aluminium give the busbars many years of experience, combined with continual research and
As the first Dutch Aluminium Processing Industry, since 1938, Nedal advantages. product development. Using the booklet in this brochure, you can calculate which
a=4m
a=3m
a=5m
a=6m
has specialised in the development and production of extruded specifications the busbars used in your projects must meet.
Nedal aluminium busbars Client-oriented solutions The guidelines and methods of calculations have been
• are lighter and have a greater stiffness than cables with the Nedal offers tailor-made solutions.The busbars’ specifications determined by KEMA (Dutch quality-control institute for
70
aluminium profiles.
same current transfer capacity are fully adapted to suit each individual client’s requirements. electrical material and appliances). Of course, the specialists
Nedal supplies its quality products to clients all over the world. - this facilitates larger free spans; at Nedal’s Technical Centre will be only too please to
a=2m
- which require fewer points of support (and foundations); Maintenance-free and environmentally friendly calculate these specifications for you, or offer you advice on
Thanks to our many years of experience, modern production
60
- the load on the foundation points is lower than is the Thanks to aluminium’s natural properties, aluminium busbars them.
techniques and, particularly, our client-oriented approach, our clients case with cables require hardly any maintenance. Because corrosion is not an
50
circuiting Of course, the fact that aluminium busbars can be recycled
• are good conductors, thanks to the skin effect: a busbar’s also benefits the environment.
a=1m
Nedal supplies special aluminium busbars for the power surface has a current density that is relatively lower than
40
that of a cable. Tailor-made
connections in open-air switching stations in high-voltage systems. • are permanently corrosion-resistant Nedal ensures that its busbars possess the optimal specifica-
• possess excellent electric conductance properties tions and metallurgical properties required for each
In these strategic points in the power supply, the busbars are a very • have a smooth surface individual situation. After consultation with the client, Nedal
30
• are maintenance-free determines the alloy and dimensions required.Throughout
reliable alternative to cable connections, and they are attractive in a
• have a very long life span the production process, the specifications are monitored
technical and economical sense too. closely.This starts at the melting process, and extends
through to packaging and dispatch.
20
10
0
L = 10 m L = 8 m L = 6 m
100
200
300
Section modulus as function of short-circuit current, phase-to-phase
400
500
distance (a) and required span (L) 6101B T7
L = 15 m
600
700
6101BT7
800
900
1000
L = 20 m
Figure 4.
In the melting furnaces, the alloy The alloy leaves the casting pit in The billets are homogenised before Precise measurements and checks Nedal extrudes the busbars from A protective packaging ensures that
required is produced precisely the form of billets busbars are extruded from them throughout the production process one piece, exactly according to the the busbars arrive at their destina-
guarantee an optimal product dimensions required, up to lengths tion undamaged and ready for instal-
of 28 metres lation
T E C H N I C A L S P E C I F I C AT I O N S N E DA L B U S B A R S
DETERMINING BUSBAR CROSS-SECTION
This part of our documentation describes a method for determining the right choice of
busbar cross-section.This method was formulated in co-operation with KEMA in Arnhem,
the Netherlands.
Based on these details a correct choice of busbar diameter and wall thickness can be made
using the method described below.
The dimensions of a busbar are mainly determined by two physical loads, i.e. the thermal
and mechanical loads on the busbar.
MATERIAL PROPERTIES
The alloys listed below, which comply with EN 755-2, are those most commonly used for
electrical busbars. Alloy 6101B T6 has more mechanical strength but less electrical
conductivity. If higher electrical conductivity is required, alloy 6101B T7 can be used.
However, this alloy has less mechanical strength. Of course busbars made of other alloys
can also be supplied. Please contact Nedal Aluminium B.V. for further information about the
properties of these alloys.
6101B T6 6101B T7
Specific gravity ρ kg/m3 2,700 2,700
Young’s modulus E N/mm2 70,000 70,000
Stress corresponding to the yield point (Rρ) N/mm2 160 120
Ultimate tensile strength (Rm) N/mm2 215 170
Elongation % 8 12
Coefficient of linear expansion ∂ (0 - 100°C) K-1 23.5x10-6 23.5x10-6
Electrical conductivity (at 20°C) MS/m (m/Ωmm2) 30 32
When the amount of heat absorbed by the busbar is the same as the amount of heat it
emits, equilibrium is reached. In this situation the busbar temperature will remain constant.
The current at this point of equilibrium is the current-carrying capacity of the busbar.
This heat balance must be considered under normal operating conditions and under the
extreme condition of a short-circuit. During a short-circuit extra heating of the busbars
may occur in a short space of time.
The allowable currents for the busbar dimensions and standard aluminium alloys available
from Nedal are given in table 2 and table 3.
It can be seen from the tables that when using aluminium alloy 6101B T7 for a current-
carrying capacity of 3000 A, the minimum busbar dimensions (diameter/wall thickness) of
100/10, 120/6 or 160/4 are acceptable.
For different ambient temperatures or final busbar temperatures the current carrying
capacity can be determined using the load factor from figure 1.
Example:
At an ambient temperature of 30°C and a final busbar temperature of 65°C, the current
carrying capacity from table 2 or 3 has to be multiplied by a factor 0.86.
If, under these conditions, a busbar has to be selected for a nominal current of 3000 A, the
method is as follows.The fictive load on the busbar is 3000 : 0.86 = 3488 A. From the table
(6101B T7) it can then be seen that possible choices for busbar dimensions are 120/10 or
160/5.
1.7
1.6
10
1.5 20
30
1.4 35
40
1.2 60
20
65
1.1
30
1.0 35
40
0.9
45
0.8 50
0.7 55
0.6 60
0.5 65
0.4
55 60 65 70 75 80 85 90 95 100 105 110 115 120
Short-circuit
Under short-circuit conditions the final busbar temperature must not exceed 200°C, based
on an initial temperature of 80°C. Higher temperatures can affect the structure of the
aluminium alloy, which results in changes in its mechanical properties. During short-circuits
the temperature will generally remain below the allowable temperature of 200°C, based on
a busbar temperature of 80°C during normal operation.
After determining the busbar cross-section the current density during a short-circuit can be
determined.This current density (J) can be determined from the short-circuit current Ik and
the cross-section of the busbar.
Table 1. Current density (J) as a function of material type and duration of the
short-circuit current
6101B T6 6101B T7
Duration of the Jeff Jeff
short-circuit current (s) (Amp./mm2) (Amp./mm2)
In accordance with the harmonisation document ‘HD 637 Power installations exceeding
1 kV a.c.’, busbars must meet mechanical requirements that have been derived from the
following loads and operating conditions:
These loads determine the sag of the busbar under normal operating conditions.The
amount of sag depends on the stiffness of the busbar. If the busbar’s diameter and wall
thickness are determined, the sag under normal operating conditions can be determined.
This can be important for the design of a switchyard.
The sag resulting from the mass and span length of the busbar can be determined from
figure 2.
50
45
10
15
5
4
63x7
40x6
40x4
100x
160x
63x3
100x
160x
40
35
15
x20
0
x5
50x8
50x4
4
80x1
120x
80x4
120x
200
200
30
Sag (cm)
25
10
4
0x
0x
22
22
20
15
4
0x
0x
30
30
15 10
15 0x
10
40
0x 0x
40
4
25
0x
15
25
0x 8
35 0x
35
10
f
5 A B
L
6 8 10 12 14 16 18 20 22 24 26 28 30
Span (m)
Figure 2. Busbar sag as function of span length (as a result of the mass
of the busbar itself)
Only forces on the busbar during short-circuits are considered below, since these forces
are the determining factor in most cases.
In a three-phase system with three busbars in the same plane, the greatest force during
short-circuits will occur in the centre busbar. Electromagnetic forces will occur between
the conductors as a result of the short-circuit current.The busbar must have a certain
stiffness to absorb these forces.The required section modulus was determined in
accordance with the simplified calculation method of IEC 865.
Based on the required short-circuit current and phase-to-phase distance, the
electromagnetic force per metre busbar can be determined using figure 3 and figure 4
(depending on the alloy used).With this data and the required span length the required
section modulus can be seen.
Criteria:
The following busbar dimensions (diameter/wall thickness) are acceptable for the required
nominal current of 4000 A: 120/15, 160/8, 200/5 and 220/4 (see table 2).
Using figure 3 it can be determined that, at the given short-circuit current, phase-to-phase
distance and span length, the required section modulus is approximately 100 cm3. Among
others, the following busbar dimensions meet this requirement: 120/12, 160/6, 200/5 and
220/4.
Busbars 120/15, 160/8, 200/5 and 220/4 meet both the current carrying capacity
requirements and the requirements from the dynamic short-circuit load. Busbar 220/4 is
the lightest in weight but is vulnerable due to its small wall thickness.Therefore a choice
should be made between 120/15, 160/8 or 200/5.
After determining the diameter and wall thickness, the client’s choice of busbar may be
based on the following:
• weight saving
• standardisation of busbars to be used (possibly a preference for 120 mm type)
• sag of the busbar as a result of busbar mass (see figure 2)
• current density in the busbar as a result of short-circuits (see table 1)
• ease of working on the busbar (it is easier to weld termination pieces to busbars with
greater wall thickness)
6101B T6 6101B T7
du wd A m I Z In In
(mm) (mm) (mm2) (kg/m) (cm4) (cm3) (A) (A)
Legend
du = external diameter I = second moment
Wd = wall thickness Z = section modulus
A = cross section In = current carrying capacity
m = mass per unit length
Table 3 Current Carrying Capacity of available Busbars (inches)
Busbar temperature 80ºC at ambient temperature 35ºC
6101B T6 6101B T7
Pipe Size Schedule du wd A m I Z In In
(in) number (mm) (mm) (mm2) (kg/m) (cm4) (cm3) (A) (A)
Legend
du = external diameter I = second moment
Wd = wall thickness Z = section modulus
A = cross section In = current carrying capacity
m = mass per unit length
Figure 3. Section modulus as function of short-circuit current, phase-to-phase
distance (a) and required span (L). 6101B T6
a=3m
a=4m
L = 20 m
a=5m
a=6m
6101BT6
NEDAL ALUMINIUM NEDAL BUSBAR’S STRONG POINTS Technically perfected CALCULATION OF SPECIFICATIONS
The excellent quality of Nedal busbars is the result of many ACCORDING TO KEMA PROVISIONS
The natural qualities of aluminium give the busbars many years of experience, combined with continual research and
As the first Dutch Aluminium Processing Industry, since 1938, Nedal advantages. product development. Using the booklet in this brochure, you can calculate which
a=4m
a=3m
a=5m
a=6m
has specialised in the development and production of extruded specifications the busbars used in your projects must meet.
Nedal aluminium busbars Client-oriented solutions The guidelines and methods of calculations have been
• are lighter and have a greater stiffness than cables with the Nedal offers tailor-made solutions.The busbars’ specifications determined by KEMA (Dutch quality-control institute for
70
aluminium profiles.
same current transfer capacity are fully adapted to suit each individual client’s requirements. electrical material and appliances). Of course, the specialists
Nedal supplies its quality products to clients all over the world. - this facilitates larger free spans; at Nedal’s Technical Centre will be only too please to
a=2m
- which require fewer points of support (and foundations); Maintenance-free and environmentally friendly calculate these specifications for you, or offer you advice on
Thanks to our many years of experience, modern production
60
- the load on the foundation points is lower than is the Thanks to aluminium’s natural properties, aluminium busbars them.
techniques and, particularly, our client-oriented approach, our clients case with cables require hardly any maintenance. Because corrosion is not an
50
circuiting Of course, the fact that aluminium busbars can be recycled
• are good conductors, thanks to the skin effect: a busbar’s also benefits the environment.
a=1m
Nedal supplies special aluminium busbars for the power surface has a current density that is relatively lower than
40
that of a cable. Tailor-made
connections in open-air switching stations in high-voltage systems. • are permanently corrosion-resistant Nedal ensures that its busbars possess the optimal specifica-
• possess excellent electric conductance properties tions and metallurgical properties required for each
In these strategic points in the power supply, the busbars are a very • have a smooth surface individual situation. After consultation with the client, Nedal
30
• are maintenance-free determines the alloy and dimensions required.Throughout
reliable alternative to cable connections, and they are attractive in a
• have a very long life span the production process, the specifications are monitored
technical and economical sense too. closely.This starts at the melting process, and extends
through to packaging and dispatch.
20
10
0
L = 10 m L = 8 m L = 6 m
100
200
300
Section modulus as function of short-circuit current, phase-to-phase
400
500
distance (a) and required span (L) 6101B T7
L = 15 m
600
700
6101BT7
800
900
1000
L = 20 m
Figure 4.
In the melting furnaces, the alloy The alloy leaves the casting pit in The billets are homogenised before Precise measurements and checks Nedal extrudes the busbars from A protective packaging ensures that
required is produced precisely the form of billets busbars are extruded from them throughout the production process one piece, exactly according to the the busbars arrive at their destina-
guarantee an optimal product dimensions required, up to lengths tion undamaged and ready for instal-
of 28 metres lation