9/24/2018 BUSBAR SIZING CALCULATION

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BUSBAR SIZING CALCULATION

V.R. V Follow
Senior Consultant - Renewables … 448 42 71

Generally there are 'THREE' Factors are involved for the Fire Causes. They are"
I) Accidental.
II) Natural.
III) Incendiary.
Comparing 'THREE', the most dangerous one is 'ACCIDENTAL'. Here Electricity plays major
role for the Fire Accident most of the Times. 
There are 'THREE' Elements must be present, for a 'FIRE' to initiate. These are Oxygen, Fuel
and Heat. Electricity Plays major role to provide 'HEAT' most of the Times. 
SOURCES for the 'HEAT' in the 'ELECTRICAL SYSTEMS' :
Most of the Time, Fire happens in the Electrical Panels, Which we observed from the Existing
Cases. So it is better to mention that, Sources for the 'HEAT' in the Electrical Panels.
a) SHORT CIRCUIT.
b) OVER LOAD.
c) POOR QUALITY IN EARTHING DESIGN.
d) ABSENCE OF VENTILATION IN THE PANELS.
e) POOR QUALITY IN DESIGNING. [Ex. Under Sized Cables].
Anything else apart from the Above,...........................................Yes. That Source should be Top in
the above list.
What is that 'Important Factor'??... It is none other than 'UNDER SIZED BUSBAR IN THE
PANELS'...

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9/24/2018 BUSBAR SIZING CALCULATION

This Article Gives Clear Picture of 'BUSBAR SIZING CALCULATION' and What Care We should
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have to take 'Sizing of Busbar'. Here I will like to describe Busbar Sizing of LT & HT Panel
System. While This Methodology doesn't have any relation with 'CALCULATION OF
CONDUCTOR BUS SIZING [ACSR]' for the Switch yard Projects. Both Calculations having
different Steps & Procedure to find Final Results.
The 'Electrical Design Engineer' Should have in-depth knowledge of 'Sizing of BUSBAR for the
Electrical Panels [Both HT & LT]. I have seen many times in my past experience, Most of the
Engineers doing Busbar Sizing Calculation by 'Thumb Rule' Method, Even though Some of
the Senior Engineers in the Consultant offices & Leading Panel Fabricator will Practice the
Same 'THUMB RULE' method. 
There are methods are exist in the world, To determine Proper sizing of Busbar for the
Electrical Systems. People not have that much Patience for the Practicing Calculation. Now
Software available to determine Proper Size of Busbar for the panels. I would like to add more
inputs in this article, which I had experienced in my past years.
THUMB Rule for Busbar :
For Aluminium       :   0.7 Amps / 1 Sq.mm of  Bar.
For Copper               :   1.2 Amps / 1 Sq.mm of Copper.
Here the above mentioned rules are not standard. Because some case people will add
Tolerance in the Positive End. i.e They used 0.75 Amps / 1 Sq.mm of Bar & 1.4 Amps / 1
Sq.mm for Aluminium & Copper Respectively. 
The Cost of the Aluminium bar in the Market based on the Quality. While Practicing 'THUMB'
Rule people should aware the Quality Standards of Aluminium & Copper Bar. Sometimes we
didn't aware the bar Quality which is used by the fabricator in the Panel. Panel Fabricators
should not take responsible in case Panel gets fire due to the Busbar Under Sized. It will
directly hit EPC Contractor Market Value in the Industry.Also it leads to Black Mark in their
Industry. He should have to answer Client, Electrical Inspectorate & Consultant. So People
should take More Care for Busbar Sizing for both LT & HT Panels. 
I would like to share one of the Example I experienced in my past. Consultant given Busbar
Size for the Main MV Panel. [That Panel should cater 10 MW of Power of the IT Building, Panel
gets power from 3 Transformers & 6 Generators]. Panel should capable to Carry 6300A.
Busbar Size Should be Equal or More than of 6300A. Consultant Recommended Busbar Size
based on the 'THUMB Rule' We noticed, Busbar Size is Low to Carry 6300A. Consultant
Challenged Contractor that, His recommended Size of Busbar will carry full load Current, then
Contractor approached 'CPRI Testing for their internal verification. Finally Busbar gets melted
when it carried full load Current [6300A] for the interval 1 Minute. Here it is not the case for
the carrying Short Circuit Current. If Busbar doesn't able to carry the Full Load Current, then
how it will carry Short Circuit Current for the Second.???
After that we will fabricate the Panel with Proper Sizing of busbar which we derived from the
Proper Calculation. In some cases people only practicing Calculation with only consider the 'K'
Factors. There is formula exist apart from the 'K' Factors. 
The Design Engineer should consider the following points while doing 'BUSBAR SIZING
CALCULATION':
Adequate minimum required clearance between Phases and Phase to Earth.
Selection of Adequate Busbar Insulator Standoffs.
Bolting Arrangements for Continuous Busbar Connections.
Thermal Effects on Busbar and Insulator Standoffs under normal and Fault conditions. 
Electrodynamic Forces applied to Busbars and Insulator Standoffs under Fault Conditions.
Avoidance of mechanical resonance under normal operating and Fault Conditions. 

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9/24/2018 BUSBAR SIZING CALCULATION

TEMPERATURE RISE:
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Maximum Permissible Temperature Rise for bolt - connected devices, including busbars

Source Reference : IEC 62271 - 1

Co-Efficient Factors 'K' : 
The Total 'K' Factor derived from Six 'K' factors, which is listed below :
K = K1 x K2 x K3 x K4 x K5 x K6
K1 is a Function of the Number of Bars per Phase and their space.
K2 is Corresponds to the Surface Finish of the Busbars.
K3 is a Function of the Mounting Arrangement.
K4 is a Function of the Installed Location.
K5 is a Function of any Artificial Ventilation.
K6 is a Function of the Type of Current.

Busbar Clearances as per IS : 4237 - 1967

Example :
Transformer Rating : 11 / 0.433 kv, 800 kVA Transformer. What is the recommendable size of
Copper Busbar in the  LT Panel ??
If we consider 80 x 10 mm of Copper Bar, How many bars required to carry full load current
of Transformer Secondary End ?
Transformer Secondary Full load Current = 1066.72A,
Breaker Size Needed = 1250A. [Either ACB or MCCB]
According to Thumb Rule,
For Copper               :   1.2 Amps / 1 Sq.mm of Copper.
for the Area 800 Sq.mm [80 x 10 mm], Current Carrying Capacity will be 960A.., Then
additional one Run of Busbar needed to carry the Current of 1067A.
According to the Formula as per IEC 62271 - I
K = K1 x K2 x K3 x K4 x K5 x K6
K = 1 x 1 x 1 x 0.8 x 1 x 1 = 0.8

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9/24/2018 BUSBAR SIZING CALCULATION

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According to the Main Formula, Derived Value will be = 1547A

Rated Current = 0.8 x 1547 A = 1238 A
Conclusion:
To Carry the Current of 1067 A, One Run of 80 x 10 mm of Copper Bar is enough.
Cheers !!!

V.R. V
Senior Consultant - Renewables … Follow

42 comments

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Mahmoud Dawoud 1mo

Senior Electrical/Automation Engineer at Rajhi Steel

many thanks for you please , you can provide us by K factors charts or tables . 
Like Reply

nagaraj nayak 2mo

How u got main formula 1547A

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Taimur Arshad Siddiq 3mo

Electrical Engineer with 7+ Years of experience

Could you please answer the same question as Mr. Ayobami has asked i.e "What do
you mean by additional run of bar needed" ?
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David Ayobami 3mo

Electrical Engineer. Power, Machines & Industrial Services

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9/24/2018 BUSBAR SIZING CALCULATION

What do you mean by additional run of bar is needed. Also why is the capacity of
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the bar when thumb rule was used is lower than FLA at the xformer secondary and
you said the size of that bar is suitable.
Like Reply

Abdulrazeg Bargathi 4mo

Automation Engineer at Private

very good information I'm very thankfull

Like Reply

Engr Md.Sohag Hossain 4mo

Head of Technical & Seals [ Online UPS -ARTronic Origin Turkey,Tescom,Kstar,East,AVR,Sub-Station
,Auto Cad ,SLD,LPS etc.

Plz tell about main formula calculation. ..

Like Reply 4 Likes

Maaz Khan 8mo

Student at INDUS UNIVERSITY

Plz tell about main formula calculation. ..

Like Reply 6 Likes

Herbert Tukakgomo 8mo

Estimator at ACTOM (Pty) Ltd

Most engineers thumb suck and end up over rating the busbars
Like Reply

Wilfred Vaz 9mo

sales manager, projects and sales, key accounts manager, technical manager,

Very useful and informative 👍

Like Reply

Sahil Asadi 10mo

Student at Aburaihan University

Please give more information about the above example to me.

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Mahmood Momenzadeh 10mo

Tender Dept. at MBNCO (Mabna Behineh Sazan Co.

Please send me calculation

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9/24/2018 BUSBAR SIZING CALCULATION

Md Mostafa Shahid Sign in10moJoin now

Sr. Technician (Ac/Dc Motor winder) at (KBIL) KSRM STEEL PLANT LTD. KABIR GROUP OF INDUSTRIES

what is voltage...??
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