DOC NO.

1805-E33-400-007

CLIENT: PROJECT
NO.
1805

Sheets No. 1 of 59

PROJECT
EPC TITLE
SRS Tankage and Terminal work
CONTRACTOR:
LOCATION Hamriyah, Sharjah, UAE

BUS DUCT INSTALLATION MANUAL

PO Number 101900070

Vendor name START ELECTRICAL SWITCHGEAR ASSMBLY LLC

Supply item BUSDUCT

VENDOR DOCUMENT / DRAWING REVIEW STAMP

Chemietech DMCC
Project Name : 1805 - SRS Tankage and Terminal work, Hamriyah,
Sharjah, UAE
A APPROVED
APPROVED WITH COMMENTS, PROCEED FOR FURTHER
B
WORK SUBJECT TO COMMENTS INCORPORATION.
C NOT APPROVED, REVISE AND RESUBMIT
D RETAINED FOR INFORMATION
Reviewed By : AJD DATE : 19.09.2019

REVISION

00 10-Sep-19 Issued for information AK SA RAFI

REVISION
DATE DESCRIPTIONS PREPARED BY CHECKED BY APPROVED BY
NO

THIS  DOCUMENT,  DATA  OR  ANY  INFORMATION  CONTAINED  HEREIN  IS  CONFIDENTIAL  BEING  THE  PROPERTY  OF  CHEMIE  TECH.  NO  CONTENTS  OF  THIS  DOCUMENT  DATA  OR 
INFORMATION SHALL BE REPRODUCED EITHER IN PART OR FULL IN ANY MANNER WHATSOEVER OR DISCLOSED TO ANY OTHER PARTY OR USED BY ANY OTHER PARTY FOR WHATEVER 
PURPOSE WITHOUT THE WRITTEN APPROVAL OF CHEMIE‐TECH. THIS DOCUMENT DATA AND INFORMATION IS FOR THE EXPRESS USE OF THE CLIENT MENTIONED. 
 BUS DUCT INSTALLATION MANUAL
Sustainable Reliable Solutions

Project No.: 1805  1805-E33-400-007

REVISION LOG

REV
REV DATE REVISED PAGE REVISION DESCRIPTION
NO.

0 07-Sep-19 Page 1 to 59 Issued for information

1805-E33-400-007-Rev-00- BUS DUCT INSTALLATION MANUAL Page 2 of 59

 INTRODUCTION

This manual is designed to assist you in installing, maintaining and

commissioning and this manual is a collection of practical information, and
proposes general recommendations complementary to the installation
regulations, which details the fundamental instructions needed for handling,
storage, installation and maintenance of RR busduct.
This manual is designed to for in installing, maintaining and
commissioning.

Note:-
Before installing the system on the site, you must read and
follow the instructions on storage,
transport and handling.

Manual overview

General information: Brief overview of busbar trunking system components and how
they are installed

Installation: Description of how the busbar trunking system elements are installed.

Inspection, expansions, checks: Description of how to handle the busbar trunking

system once it has been installed.

Warning:-
 Handling
Busbar trunking system elements can be moved using
a forklift and/or suspended from slings.

Use fabric slings to suspend the busbar trunking

system elements.

Ensure that the elements do not get damaged when

transporting them with a forklift.

Busbar trunking system elements can be stored in 01

clean and dry place.
Suspension from slings

Safe handling
As with all electrical equipment, this material should be handled with care, following the
instructions.

Proceed with caution and pay attention to personnel safety. Use all equipment necessary
for correct handling of the material.

03
Suspension from slings

02

Transport using a forklift

 Packaging
The busbar trunking system elements are supplied with
protective covers on their ends.

01 Storing double stack systems Flat wise

Handling
Busbar trunking system elements can be moved using
a forklift and/or suspended from slings.

Ensure that the elements do not get damaged when

transporting them with a forklift.

Busbar trunking system elements can be stored in

clean and dry place.

02 Storing single stack systems Edge wise

Storage
The material storage area has to meet the following requirements:-

1 - It must be stable, secure and not on a slope.

2 - It must be protected against damp, extreme temperatures and water penetration.
3 - Effective protection against dust, water, welding sparks and other factors that could damage
the material supplied must be in place.
Joint Block single stack installation

Copper 800A ~ 2000A

Aluminum 800A ~ 2000A

N
mm
285

Bottom Joint Cover

02
M8 Washer

M8 Allen Screw

01

Joint Assembly

Joint Assembly

03 04

Check the distance between the elements again and ensure that it is 285 mm.
Joint Block single stack installation

Copper 800A ~ 2000A

Aluminum 800A ~ 2000A

Spanner

Shear off nuts

05 06

07 08

Check the distance between the elements again and ensure that it is 285 mm.
Joint Block double stack installation

Copper 2500A ~ 6300A

Aluminum 2500A ~ 5000A
N
mm
285

Bottom Joint Cover

M8 Washer
M8 Allen Screw

01
02

Joint Block Joint Block

04

03

Check the distance between the elements again and ensure that it is 285 mm.
Joint Block double stack installation

Copper 2500A ~ 6300A

Aluminum 2500A ~ 5000A

06
Shear off nuts
05

07 08
Tap- Off box installation

01

02

03
Locking Leg
Tap- Off box installation

04

A B C
Horizontal Fixing single stack

Edgewise installations Flatewise installations

Horizontal Fixing double stack

Flatewise installations

Edgewise installations
Vertical spring hanger
Busbar Riser

Vertical Spring Hanger assembly

Floor Slab

Vertical Spring
Hanger assembly
Vertical Spring
Hanger assembly
Horizontal Fixing

Unistrut channel 41 x 41
not in RR scope

Unistrut channel 41 x 41
not in RR scope

Busbar trunking system on a spring hanger for vertical installation on the floor.

Spring Hanger are used to support weight of a vertical

installation and compensate for minimal building movement and thermal expansion.
End Cover single stack

End Cover

02
PVC Sheet

01

04

03

05
06
End Cover double stake

End Cover

PVC Sheet

02
01 04

03

05

06
 ASTA Publication 7 Issue 10

ASTA Certificates, ASTA Licences and ASTA Test Reports

ASTA Certificates, ASTA Licences and ASTA Test Reports are issued by Intertek for the exclusive use
of the party applying for the Certificate, Licence or Test Report and any related testing. Intertek assumes
no liability to any parties other than those with which it has an agreement and then only in accordance
with the agreed Terms and Conditions.
The Applicant is authorised to copy or distribute ASTA Certificates, ASTA Licences and
ASTA Test Reports provided the entire contents are included, or Certificate Front Sheets accompanied
by any associated pages on which are stated the assigned rated characteristics and no part is obscured
or illegible, or Licence front sheets. Permission must be obtained from Intertek before any other kind of
reproduction is made.
The holder of an ASTA Certificate may claim in Trade Journals, Catalogues, Technical Articles etc., and
without the prior approval of Intertek that the product identified in an ASTA Certificate is ASTA Certified.
The holder of an ASTA Licence may claim in Trade Journals, Catalogues, Technical Articles etc., and
without the prior approval of Intertek that the product identified in an ASTA Licence is ASTA Approved.
To minimise the possibility of any misunderstanding such claims must clearly identify the product(s)
certified or approved, the ratings verified by ASTA and the Standard against which certification/approval
has been made.
Any other use of the Intertek or ASTA names must first be approved in writing by Intertek. Test results
and ratings proven by testing included in ASTA Certificates and ASTA Test Reports relate specifically to
the sample(s) tested.

Types of ASTA Certificates

Certificates are issued when samples of a particular product design have been tested satisfactorily
against the requirements of a National, European, International or ASTA Standard. Several forms of
Certificate are available, including:

Certificate of Complete Compliance

Verifies compliance with all the requirements of a Standard

Certificate of Type/Verification Tests

Verifies complete series of type/verification tests prescribed in a Standard has been made
successfully.

Certificate of Selected Type/Verification Tests

Verifies specified type/verification tests have been made successfully

Supplementary Certificate
Extends the scope of an existing Certificate to cover changes in rating or in design

ASTA Test Report

An ASTA Test Report is issued when tests otherwise satisfactory cannot be included in a Certificate for
one or more reasons, e.g. verification of non-standard ratings

ASTA Licences and ASTA Diamond Mark

The use of the ASTA Diamond Mark on products is authorised by an ASTA Licence. Products covered
by an ASTA Licence can be referred to as ASTA Approved. Requirements for ASTA Licences include
testing for full compliance with relevant standards and satisfactory, on-going assessment of production.
Validity and use of ASTA Licences are subject to compliance with Intertek Certification Regulations.
For more information see http://intertek.com/europeaninspection

Short-Circuit Testing Liaison (STL)

Intertek (ASTA) is a member of the Short-Circuit Testing Liaison. For further details please refer to
http://stl-liaison.org

Authenticity
Authenticity of any ASTA document can be confirmed by contacting the Intertek office detailed on the
front of this document.
` Certificate No. 21610

Laboratory Ref. No: WO-1718-016643 / ERDA-00233306, WO-1718-015377 / ERDA-00226104, WO-1718-012678

/ ERDA-00224906, WO-1718-017184 / ERDA-00237249, WO-1718-007464 / ERDA-
00212078 and ERDA-00212076, WO-1718-007799 / ERDA-00212078 and 770462/06

Page A
VERIFICATION OF THE BTS DESIGN BY TESTS

No.* Characteristic verified Clause/ Verified Tests and Ratings

Sub clause

Strength of materials and parts 10.2

1
Resistance to corrosion 10.2.2 “Severity test A” Verified

Properties of insulating materials 10.2.3 -

Verification of thermal stability of
10.2.3.1 Not applicable to metallic enclosures
enclosure
Resistance to abnormal heat and fire
10.2.3.2 Verified
due to internal electric effects
Resistance to ultra-violet (UV)
10.2.4 Not applicable to indoor enclosures
radiation
Ability to withstand mechanical loads 10.2.101 Verified

-for a straight busbar trunking unit 10.2.101.1 Heavy mechanical loads: Verified
-for a joint 10.2.101.2 Heavy mechanical loads: Verified
Resistance of the enclosure to
10.2.101.3 Heavy mechanical loads: Verified
crushing
Lifting 10.2.5 Verified
Mechanical Impact test 10.2.6 Verified: IK 10
Marking 10.2.7 Verified
External enclosure: IP 65, category 1
2 Degree of protection of enclosures 10.3
Verified
8kV (Uimp)
3 Clearances 10.4
Verified
Material Group: IIIa
4 Creepage distances 10.4 1000V (Ui) for pollution degree 3
Verified
Protection against electric shock
5 10.5 Verified
and integrity of protective circuits:
Effective continuity between the
exposed conductive parts of the BTS 10.5.2 Verified
and the protective circuit
Short circuit withstand strength of the 10.5.3.3
protective circuit

Earth busbar: (Size: 2 x 200mm x Icw = 72kA rms for 1 sec

3mm polyester wrapped tin plated Ipk = 158.4kA peak
copper bars)

* Note: Design verification tests required by IEC 61439-6, Annex D, Table D.1. No verification by testing is
required for items 6, 7 and 8 clauses 10.6, 10.7 and 10.8

Date of Tests: 28th August 2017 to 20th January 2018 M Yahia, ASTA Observer
` Certificate No. 21610

Laboratory Ref. No: WO-1718-016643 / ERDA-00233306, WO-1718-015377 / ERDA-00226104, WO-1718-012678

/ ERDA-00224906, WO-1718-017184 / ERDA-00237249, WO-1718-007464 / ERDA-
00212078 and ERDA-00212076, WO-1718-007799 / ERDA-00212078 and 770462/06

VERIFICATION OF THE BTS DESIGN BY TEST Page B

No.* Characteristic verified Clause/ Verified Tests and Ratings

Sub clause
Rated voltages:
Ue = 1000V
Dielectric properties: 10.9 Ui = 1000V for pollution degree 3
Material Group: IIIa
Uimp = 8kV
9
Power-frequency withstand voltage 10.9.2 Verified

Alternative Power-frequency voltage test 10.9.3.3 Verified

10 Temperature rise limits 10.10.2.3.5

The rated current of the BTS was based 50/55°C

upon a mean/maximum ambient
temperature of

Rated current of main busbars: 5000A

(2 x 200mm x 6mm polyester wrapped tin
plated copper bars per phase)
(Horizontal Orientation)
11 Short-circuit withstand strength 10.11
Incoming circuit & main busbars:

Main phase busbars 10.11.3 Icw = 120kA rms for 1 sec

(Size: 2 x 200mm x 6mm polyester Ipk = 264kA peak
wrapped tin plated copper bars per
phase )
Neutral Conductor

Main Neutral busbar 10.11.3 Icw = 72kA rms for 1 sec

(Size: 2 x 200mm x 6mm polyester Ipk = 158.4kA peak
wrapped tin plated copper bars)
12 Electromagnetic compatibility 10.12 Conditions for no testing verified

13 Mechanical operation 10.13 Conditions for no testing verified

Date of Tests: 28th August 2017 to 20th January 2018 M Yahia, ASTA Observer
`

Laboratory Ref. No: WO-1718-016643 / ERDA-00233306, WO-1718-015377 / ERDA-00226104, WO-1718-012678

/ ERDA-00224906, WO-1718-017184 / ERDA-00237249, WO-1718-007464 / ERDA-
00212078 and ERDA-00212076, WO-1718-007799 / ERDA-00212078 and 770462/06

Page C

VERIFICATION OF PHASE CONDUCTOR CHARACTERISTICS (Annex BB of IEC

61439-6: 2012):

Determination of the resistance, reactance and impedance value of the system in

accordance with Annex BB

Rating of the
Busbar Trunking X μΩ/m R20 μΩ/m Z20 μΩ/m R35 μΩ/m Z35 μΩ/m
System Assembly

5000A 25.33 0.81 25.34 0.99 25.35

Date of Tests: 28th August 2017 to 20th January 2018 H. K. Mishra, ASTA Observer