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Power Engineering
Busbar Home
A
bus bar (also spelled busbar, buss bar or busbar), is ABOUT ME
a strip or bar of copper,
brass or aluminum that
Bhagwan Prasad
conducts electricity within a switchboard, Panipat, Haryana, India
distribution
board, substation, battery bank or other
Chartered Engineer in
electrical apparatus. Its main purpose
is to conduct
Electrical Engineering having
electricity, not to function as a structural member.
20 years experience in Power Distribution,
Busbars are typically
either flat strips or hollow Electrical Maintenance, Electrical Projects,
tubes as these shapes allow heat to dissipate more basic of SAP, Design, estimation and
efficiently due to their high surface area to cross- costing of power distribution,EPC for indoor
sectional area ratio. A
hollow section has higher substation,street lighting, Language with
stiffness than a solid rod of equivalent
current- English, Hindi, Bhojpuri Keen interested in
carrying capacity, which allows a greater span Sharing information/experience and help
between busbar supports
in outdoor switch yards. technical enthusiasts to update themselves
on various Engineering Topics. CONTACT
A busbar may either be
supported on insulators, or
:amieclub@gmail.com
else insulation may completely surround it. Busbars
are protected from accidental contact either by a View my complete profile
Bus bar
metal earthed enclosure or by
elevation out of
normal reach. Power Neutral busbars may also be insulated.
Earth (safety grounding) BLOG ARCHIVE
busbars are typically bare and bolted directly onto
any metal chassis of their enclosure. ►
2021
(1)
Busbars may be enclosed in a metal
housing, in the form of bus duct or busway,
►
2020
(9)
segregated-phase bus, or
isolated-phase bus.
Busbars may be
connected to each other and to electrical apparatus by bolted, clamp, or ►
2019
(3)
welded
connections. Often joints between high-current bus sections have matching ►
2018
(9)
surfaces that are silver-plated to reduce the contact resistance. At extra-high
voltages
►
2017
(5)
(more than 300 kV) in outdoor buses, corona around the connections
becomes a source of
radio-frequency interference and power loss, so connection
fittings designed for these ►
2016
(3)
voltages are used. ►
2015
(26)
Busbars are typically
contained inside switchgear, panel boards, or busway. Distribution
►
2014
(5)
boards split
the electrical supply into separate circuits at one location. Busways, or bus
ducts, are long busbars with a protective cover. Rather than branching the main
supply at ▼
2013
(21)
one location, they allow new circuits to branch off anywhere along
the route of the ►
November
(2)
busway. ▼
October
(4)
Advantages Busbar size and calculation
Following are some advantages of Bus bar
trunking system over normal cabling system:-
1.
On-site installation times are reduced
compared to hard-wired systems, thus leading to Voltage drop calculation in cable
cost savings. Cable current rating
2.
It provides increased flexibility in
design and versatility with regard to future Cable laying abstract
modifications.
3.
Greater safety and peace of mind for
specifiers, contractors and end-users. ►
September
(2)
4.
Because of the simplicity of busbar, it
is easy to estimate costs from the design/estimating ►
August
(1)
stage through to
installation on site. This is because
the technical characteristics and
►
July
(4)
price of each component are always known.
5.
It is short sighted to compare the cost
of busbar against that of a length of cable — and ►
June
(3)
not the real cost of a cable
installation to include multiple runs of cable, tray and fixing, ►
May
(4)
let alone the
protracted time and effort of pulling cables.
►
April
(1)
6.
Distribution busbar distributes power
along its length through tap-off points along the
busbar at typically at 0.5 or
1 m centers. Tap-off units are plugged in along the length of ►
2012
(54)
the busbar to
supply a load; this could be a sub distribution board or, in a factory, to
individual machines. Tap-offs can normally be added or removed with busbar
live,
eliminating production down time. FOLLOWERS Report Abuse
7.
Installed vertically the same systems
can be used for rising-mains applications, with tap-
offs feeding individual
floors. Certified fire barriers are available at points where the
busbar passes
through a floor slab. Protection devices such as fuses, switchfuses or circuit
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9/28/21, 11:10 AM Power Engineering: Busbar size and calculation
breakers are located along the busbar run, reducing the need for large
distribution boards Followers (226)
Next
and the large quantities of distribution cables running to
and from installed equipment.
8.
Very compact so provides space savings.
9.
Where aesthetics have to be considered,
busbar trunking can be installed with natural
galvanized, aluminium, or painted
finish. Special colours to match switchboards or a
specific colour scheme are
also available on request.
10.
Busbar trunking has several key
advantages over conventional forms of power
distribution including: -
11. (a)
Reduced, onsite installation times when compared to hard-wired systems thus
leading
to cost savings.
a. Increased flexibility in design and
versatility with regard to future
modifications.
b. Increased safety features brought about by the
use of high quality,
manufactured components, which provide greater safety and
peace of mind
for specifies, contractors and end-users.
12. Uneven
distribution of current takes place where multiple runs of cables are used in
Follow
parallel.
13.
Busbar trunking has tap-off points at
regular intervals along each length to allow power to
be taken off and
distributed to where it is needed. Because it is fully self-contained it LABELS
needs
only to be mechanically mounted and electrically connected to be operational.
transformer metal content
14.
For higher ratings of power distribution
we need to have multiple runs of cable. In such
conditions unbalanced
distribution of current takes place and causing overheating of some
cable. This
is completely avoided in the BTS systems.
15.
When multiple runs of cables are used it
often leads to improper end connections thereby
causing overheating of
contacts, burning of cables ends, and is a major cause of fire. This
is
completely avoided in Bus Bar Trunking systems.
Current
carrying capacity
The current-carrying
capacity of a busbar is usually determined by the maximum
temperature at which
the bar is permitted to operate, as defined by national and
international
standards such as British Standard BS 159, American Standard ANSI
C37.20, etc.
These standards give maximum temperature rises as well as maximum
ambient
temperatures.
BS 159 stipulates a
maximum temperature rise of 50°C above a 24 hour mean ambient
temperature of up
to 35°C, and a peak ambient temperature of 40°C.
ANSI C37.20 alternatively
permits a temperature rise of 65°C above a maximum ambient
of 40°C, provided
that silver-plated (or acceptable alternative) bolted terminations are
used. If
not, a temperature rise of 30°C is allowed.
A very approximate
method of estimating the current carrying capacity of a copper busbar
is to
assume a current density of 2 A/mm2 (1250 A/in2) in still air. This method
should
only be used to estimate a likely size of busbar, the final size being
chosen after
consideration has been given to the calculation methods. Refer
catalogue of
manufacturers.
The more popular thumb
rule being followed in India is to assume current density of 1.0
Amps / Sq.mm
for Aluminium and 1.6 Amps for Copper for any standard rectangular
conductor
profile.
Standard
size of bus bar
Sr. Application Cable busbar
area
1 Number
of One
circuit per floor. Just
one circuit can cover all floors.
circuits Hence for a 20-floor
building, you need 20
circuits.
2 Main Need
1 outgoing for Need
only 1 outgoing for each riser.
Switchboard each circuit. Hence 20 Lower cost and size of main panel.
nos. MCCB outgoings.
Higher cost and
larger
space requirement in
electrical room
3 Shaft
Size Using
4 core cables, Typical
size of 1600A riser is
and considering 1 185mm x 180mm. Leads to big
cable per feeder, you savings on riser shaft
size, and hence
need 20 cables on the more usable floor area on every
lowest floor. Large floor.
space required for
cables/ cable tray.
4 Fire
& safety The
high concentration The
volume of insulating materials
of insulating materials used in trunking is reduced to a
used in cables and minimum so
combustive energy is
conductors
involves a considerably lower than cables. The
very high level of insulating materials
used do not
combustive energy. release corrosive or toxic gases in the
event of a fire. Once the
source of
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9/28/21, 11:10 AM Power Engineering: Busbar size and calculation
the fire is removed, these materials
are extinguished in a few
seconds so
that the effect of the fire is
minimised
5 Future load
on any floor By
providing extra tap off slots on
expansion exceeds initial plan, each floor at the design stage, owner
owner has to run an only
has to procure a tap off box and
additional cable from
a plug it in wherever additional load is
spare feeder on main required. As the plug in can be done
board to that floor. live, there is no shut down required
for
any of the existing clients /
circuits. Future Flexibility.
6 Fault Limited
by conductor Much
higher – typically a 1600 A
withstand size of each circuit. riser has a fault withstand capability
levels of 60 to
70 kA. Safer in an electrical
fault.
7 Installation Much
longer Each
riser on a 20-floor building can
time be installed in approximately 2 to 3
days.
8 Voltage
drop High
impedance if you Much
lower impedance. Hence
choose cable size substantially lower voltage drop.
based on each floor
current rating.
Busbars
Reduce System Costs
A laminated busbar will
lower manufacturing costs by decreasing assembly time as well
as internal
material handling costs. Various conductors are terminated at customer
specified locations to eliminate the guesswork usually associated with assembly
operating
procedures. A reduced parts count will reduce ordering, material
handling and inventory
costs.
Bus
bars Improve Reliability
Laminated bus bars can help your organization
build quality into processes. The
reduction of wiring errors results in fewer
reworks, lower service costs and lower quality
costs.
Bus
bars Increase Capacitance
Increased capacitance results in decreasing
characteristic impedance. This will ultimately
lead to greater effective signal
suppression and noise elimination. Keeping the dielectrics
thin and using
dielectrics with a high relative K factor will increase capacitance.
Eliminate
Wiring Errors
By replacing a standard
cable harnesses with bus bars, the possibility for miss-wirings is
eliminated.
Wiring harnesses have high failure rates relative to bus bars, which have
virtually none. These problems are very costly to repair. Adding bus bars to
your systems
is effective insurance.
Bus
bars Lower Inductance
Any conductor carrying current will develop an
electromagnetic field. The use of thin
parallel conductors with a thin
dielectric laminated together minimizes the effect of
inductance on electrical
circuits. Magnetic flux cancellation is maximized when opposing
potentials are
laminated together. Laminated bus bars have been designed to reduce the
proximity effect in many semiconductor applications as well as applications
that involve
high electromagnetic interference (EMI).
Bus
bars Lower Impedance
Increasing the capacitance and reducing the
inductance is a determining factor in
eliminating noise. Keeping the dielectric
thickness to a minimum will accomplish the
highly desired low impedance.
Bus
bars Provide Denser Packaging
The use of wide, thin conductors laminated
together led to decreased space requirements.
Laminated bus bars have helped
decrease total system size and cost.
Bus
bars Provide Wider Variety of Interconnection Methods
The flexibility of bus bars has allowed an
unlimited number of interconnection styles to
choose from. Bushings,
embossments, and fasten tabs are most commonly used.
Bus
bars Improve Thermal Characteristics
The wide, thin conductors are favourable to
allowing better airflow in systems. As
package sizes decrease, the cost of
removing heat from systems has greatly increased. A
bus bar cannot only reduce
the overall size required, but it can also improve airflow with
its sleek design.
Material:
The copper will be of ETP grade as per DIN 13601-2002 and with oxygen free
copper.
Chemical
composition: Purity of copper will be as per DIN EN 13601:2002. Copper +
Silver
99.90% min.
Typical example
Rating
Current: 3200Amp.
System:415Vac,
TPN, 50Hz.
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9/28/21, 11:10 AM Power Engineering: Busbar size and calculation
Fault
Level: 50KA. For 1 Sec.
Operation
Temp:40° C rise over 45 ° C ambient.
CONSIDERATION
Enclosure
size: 1400 mm. wide X 400mm. height
Bus
bar Size: 2:200x10 per Ph., 1:200x10 for Neutral.
Bus
bar material: Electrolytic gr. Al. (IS 63401/AA6101)
The
minimum cross section needed in sqmm for busbar in various common cases can be
listed as below-
35 285 127 57 28
Copper 50 407 182 81 41
65 528 236 106 53
Let
us select a busbar with an example:
1) Aluminium
busbar for 2000A, 35 kA for 1 sec withstand – From the table the
minimum
cross-section needed would be 443 mm2. Thus we can select a 100mm x 5mm
busbar
as the minimum cross-section. Considering a current density of 1A/ mm2
by
considering temperature as well as
skin effect, we shall require 4 x 100mm x 5mm
busbars for this case.
2) Copper
busbar for 2000A, 35 kA for 1 sec withstand – From the table the minimum
cross-section needed would be 285 mm2. Thus we can select a 60mm x 5mm busbar
as
the minimum cross-section. Considering a current density of 1.6A/ mm2 by
considering
temperature as well as skin effect, we shall require 4 x 60mm x 5mm
busbars for this
case.
40X10 400 3.55 760 1350 1850 2500 770 1400 2000
50X5 250 2.22 630 1100 1650 2100 650 1150 1750
50X10 500 4.44 920 1600 2250 3000 960 1700 2500
60X5 300 2.66 760 1250 1760 2400 780 1300 1900 2500
60X10 600 5.33 1060 1900 2600 3500 1100 2000 2800 3600
80X5 400 3.55 970 1700 2300 3000 1000 1800 2500 3200
80X10 800 7.11 1380 2300 3100 4200 1450 2600 3700 4800
100X5 500 4.44 1200 2050 2850 3500 1250 2250 3150 4050
100X1 1000 8.89 1700 2800 3650 5000 1800 3200 4500 5800
0
120X1 1200 10.7 2000 3100 4100 5700 2150 3700 5200 6700
0
160X1 1600 14.2 2500 3900 5300 7300 2800 4800 6900 9000
0
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9/28/21, 11:10 AM Power Engineering: Busbar size and calculation
200X1 2000 17.8 3000 4750 6350 8800 3400 6000 8500 1000
0 0
Temperature rise
During
the short circuiting, the bus bar should be able to withstand the thermal as
well as
mechanical stress. When a sort circuiting takes place, the temperature
rise is directly
proportional to the squire of the rms value of the fault
current. The duration of short
circuiting is very small i.e. one second till
the breakers opens and clears the fault. The
heat dissipation through
convection and radiation during this short duration is negligible
and all the
heat is observed by the busbar itself. The temperature rise due to the fault can
be calculated by applying the formulae.
T
= K (I/A) 2 (1+αθ) 10-2
T=temperature
rise per second
A=
conductor cross section area
α
= temperature coefficient of resistivity at 20 deg.C/deg.C
= 0 .00393 for copper
= 0 .00386 for aluminium
K
= constant
=0.52 for copper
=1.166 for aluminium
θ
= temperature of the conductor at the instant at which the temperature rise is
being
calculated.
Typical calculation
Rated
current = 1000A
Fault
current = 50KA for 1 sec
Permissible
temperature rise= 40 deg.C
Busbar
material =aluminium ally E91E
De-rating
factor due to material =1
De-rating
factor due to temperature rise =0.86
De-rating
factor due to enclosure =0.75
Total
de-rating factor = 1x0.75x0.86=0.66
Minimum
cross section area required to withstand short circuit for 1 sec.
= (Ifc x√t
)/0.08
Where,
Ifc = fault level current in KA
t= 1 second
Area
A = (50x√1
)/0.08 = 625 sqmm
Considering all de-rating factor, A = 625/0.66
=946.97
Say,
cross sectional area per phase = 1000 sqmm
For
neutral, cross sectional area per phase = 500 sqmm
for more study -refer a practical guide to cable installation and tool box talk
In India -
Price:
Rs. 375/- excluding delivery charges
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9/28/21, 11:10 AM Power Engineering: Busbar size and calculation
at
October 27, 2013
82 comments:
http://www.sanjaytechnical.in/11kv-bus-duct/11kv-bus-duct.html
Reply
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SO 40X6=240
Reply
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9/28/21, 11:10 AM Power Engineering: Busbar size and calculation
Replies
IF BUSBAR IS OF 40X6 MM
SO 40X6=240
Reply
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Reply
As per my requirement, I am searching Bus Bar Cross Section (Thickness & Width) for
3A, 5A, 10A, 30A, 40A, 100A, 250A Current rating.
----------------------------------------
| Mail. : ankur.afre@hindujatech.com |
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generators
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9/28/21, 11:10 AM Power Engineering: Busbar size and calculation
Use this calculation for selection of busbar
Ampacity=Width*Thk*1.55
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Servomax Limited
Servo Stabilizers
Servomax Ltd
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9/28/21, 11:10 AM Power Engineering: Busbar size and calculation
and Outgoing 6300A (we Required maximum no of Run 2). bus bar Copper.
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I want to select busbar for HT panel . Calculated regular load 800 Amp.
So which busbar is suitable for the this HT panel i.e. Al. Or Cu.
And how , what calculation are considered and also consider the fault current if fault
occurs at site.
Sir please reply with all calculations and consideration means it will clear to me to
explain
Kiran.bhalsinge@gmail.com
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9/28/21, 11:10 AM Power Engineering: Busbar size and calculation
for detail: "a practical guide to cable installation and toolbox talk".
regards
amieclub@gmail.com team
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For Electrostatic Precipitator, secondary side of transformer having 50kV high voltage
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9/28/21, 11:10 AM Power Engineering: Busbar size and calculation
drawn 30mA to 100mA current.
can I use copper busbar to connect ESP with Transformer secondary and if yes what will
be size of copper bus bar.
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Gokul Steel is leading supplier of WPS Flat Bar and Round Bar Supplier in Ahmedabad.
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9/28/21, 11:10 AM Power Engineering: Busbar size and calculation
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