33 ELECTRICAL DESIGN OF SWITCHGEAR ASSEMBLY

Bar Minimumn
Length
Width of Over A (mm) B(mm) Bolt Size
Hole Dia Tightening
(mm) lap (mm) Torque
(kgm)
25.4 50 12.5 12.5 M6/M8 6.6/9 1.5/2.5
38.1 76 19 19 M10 11 3.5
50.8 76 25 25 M12 14 5.5

For figure (a) For figure (b) For figure (c)

Forfigure (a)
Bar Length Minimum
Hole Dia
Width of Over A(mm) B (mm) Bolt Size Tightening Torque
(mm)
(mm) lap (kgm)_
76.2 76 19 19 M10 11 3.5
101.6 102 27 27 M12 14 5.5

Forfigure (b)
Bar Length Hole Dia
Minimum
Width of Over A(mm) B (mm) C (mm) Bolt Size Tightening Torque
(mm)
(mm) lap (kgm)
152.4 152 32 29 48 M12 14 5.5

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 Hecommended practices for
9.1 Recommended busbar overlaps for different sizes mounting buses and making bus joints 29/1043
and torques of fasteners
Bar Length of Bolt
overlap Dimensions Bolt size
width arrangement (Figure 29.3) Hole
as indicated
diameter
Minimum Typical size of
in Figure 29.3 recommended slots for fishplates
bolt torque
or straight
through joints
2
4 (Figure 29.4)
4 8
MM B C
mm mm mm
mm
25.4 50 kgm mm
12.5 12.5
38.1 76 M6/M8
19 19 6.6/9 1.5/2.5
50.8 76 25 M10 11
25 3.5 11x 16
76.2 76 2 M12 14
19 9 5.5 4x 18
102 MI0 11
101.6 3.5
152.4 152
27 27
M12 14
11x16
29 48 5.5 14 x 18
203.2 203 4 M12 14
29 48 5.5 14 x I8
M12 14 5.5 14 x 18
These torque values will normally require
high tensile fasteners.
For copper busbars the torque may be raised
Overlap for by 150-200% of this.
tee joints even up to the
width of bar will be adequate. Such as, for a tee
bar, 50.8 mm overlap will be
adequate, refer joint of 50.8 wide bar, with
to Figure 29.7. mm a 101.6 mm
straight
Table 29.2 Recommended sizes of punched washers
for hexagonal bolts and screws as in IS 2016 to make a good joint
Bolts size d
D
mm (max) S
mm (min.)
mm (min)
Conical Belliville washers
h (max.) mm

IS
h
M6 6.6
M8 12.5 1.6
9 2.0
M 10 11 1.6 2.6
M 12 21 2.0
14 3.2
24 2.5 3.95
Based on DIN 6796 for conical
spring washers for bolt/nut assemblies.

Notes
The above are the sizes of washers when the hole in the busbar is circular.
29.1, column 8, to facilitate
easy jointing of the fishplates or
If the hole is in the shape of a slot, as recommended in Table
as illustrated in Figure 29.4. A normal size of washer straight-through joints, then the bulk of the washer should span the slot
as noted ve lose its
failure. In such cases it may be recommended to efficacy
in the course of time, may and sag into it (by
and lead to
use either
setting), loosen its grip
Sof Table 29.3 or pressure plates or heavy washers as
normal washers may be chosen corresponding to the larger width of the slot, per
noted
in Table 29.3, to
achieve a considering this as its hole size d, as
good rigidity and stability of washers to maintain the required contact
service. over pressure long periods of
where the contact
pressure is of utmost importance, it is recommended to use conical washers (some call them Belliville washers) to
Ounteract
the loosening
of a bolt and nut assembly, caused by setting or indentation. The last column of Table 29.2 indicates the vital
dimension h for such washers as in DIN-6796.
Table 29.3
Recommended sizes of washers for slots
Slot size B
Recommended Sizes of normal washers as in
size of washer IS 2016
for slot d P-
mm D
mm mm mm mm
11x 16 I6
14x 18 21 2.5 2 3
18 14 24 3.15
Figure 29.3 Busbar bolting for Table 29.1
 Reference & Applications Handbook
29/1044 Electrical Power Engineering
Bolts M-10
Bolts M-10
- Desirable pressure

-Fish plate 40-55 kg/cm2

II
Illustrating use of
pressure plates for
large bus sections

Spring washer
Minimumn Bolt
2 threads
One section Second section
of busbar of busbar
Gap to allow for
any mismatch

76 76
-19 38 19 15-19- 38
-19 Slotted hole
(11 x16)
9 7

11
7638

19

(All dimensions in mm.)

Figure 29.4 A typical arrangement for jointing two sections of a busbar through a fish plate

4x M12 bolts

Fish plate

100

50 Bolts M-10

200- Plain washer

Desirable
pressure
40-55 kg/cm

38 Plain washer
Spring washer

Bolt
Busbar section-
18 38
14
Slotted hole_
38

50 -
100 50
(All dimensions in mm) 25 25
Figure 29.5 Another
a busbar through a fisharrangement for jointing two sections of
plate ns
Figure 29.6 Jointing of two single busbar sect
 Recommended practices for
Publication 22 of CDA (Copper Development mounting buses and making bus
joints 29/1045
UK). Association, the free ends will
absorb the small
longer lengths and when the end expansion. But for
Overlapping of joints olted at a rigid end, as at a of the bus is to be
Correct-overlapping
must be
provided at suitabletransformer, expansion joints
make good
of
joint is
well as toimportant
an
expansion of the busbars. locations to absorb the
linear
allow no parameter
a
joint, aluminium in use, the linear For the normal grade of
to
as
heat at the joints. Based on the excessive
leading aluminium section recommendations of the expansion can be considered to temperature coefficient of
overlaps are shown in Tablemanufacturers, the desired 30.1). A busbar 25 m long and be 0.000023 mm/°C (Table
are illustrated in Figures 29.4
29.1, and
and 29.6.
two such joints
of 85°C
having a temperatureoperating
ambient of 45°C will
at a
rise of 40°C temperature
above an
and site experience have revealed that a Laboratory
of no additional benefit. For
tests
larger overlap is 40x 0.000023 mm, i.e. have an
expansion
23 mm. In
of 25x 1000 x
must have free such cases, the busbars
one row of fasteners, as larger sections also, only longitudinal movement and
illustrated in provided with suitable must be
adequate to provide a reasonably good Figure 29.5, is expansion joints at reasonable
intervals, say, at every 7.5/10
the recommended contact joint, so long as bolted clamps as shown m. Busbars
55 kg/cm for aluminium pressure per unit area, of 40- in Figure supported on
this for copper) is joints (roughly 150-200% recommended as they block the linear 29.2(b) are not
maintained, as indicated earlier. of busbars, which may deform the expansion of the
damage to the insulators and the busbars and result in
29.2.2 Tee joints fault.
Finger-type busbar supports,supports and cause a
as shown in
Refer 13.31(b) must be preferred to Figure
to Figure 29.7 when
making a tee joint with a The expansion clamp type supports.
larger section of bus to
tap for the
joints may of aluminium or
thin sheets (foils 32 be
PCC or MCC from the main bus. A outgoing feeders in a copper
smaller braided wires to allowgauge and thinner) or even copper-
section will beoverlap 29.8 illustrates one suchflexibility on expansion. Figure
the width of the feeder bus up to easy
provide adequate contact area and sufficient to flexible
an
bolting surface. procedure to make a flexible joint is tojoint. The normal
fold these sheets
together and press clamp at the ends, as shown in
29.2.3 Expansion joints 29.9, where it is to be bolted with Figure
riveted at convenient locations to the bus sections. It is
During normal operation busbars To avoid hold the foils in
oxidation at the contact area, when it isposition.
a result of undergo elongation as
heating. When the busbars
PCC or are short, as in a
MCC, and have free ends, no atmospheric conditions,
weld them
it is open to
recommended to braze or
for expansion of provision to account at the edges (as noted in
busbars will be
of the structure on necessary. Expansion they are to make the joint, as shown inSection 28.4.1) where
which the busbars are mounted
and welding, inert gas, metal or tungsten arCFigures 29.8. Fusion
are recommended for welding processes
joints shown in Figure 29.9.
Cu or Al flexible
connector
(made of foils or braids)- Spring washer Plain washer

Brazing
Foil or braided
holding wrap
Main bus
Plain washer
Rivets to hold the -
flexible wraps
Slots (11 x 16)

16.8

34
101.6

Tap-off links
19
5 90 5
One section
Figure 29.7 Tap-off Second section
arge section of busbar connections
of bus
from a ofbus
showing the overlap
as equal to the width of the smaller section (All dimensions in mm)
tap-off links
Flgure 29.8 A typical flexible expansion joint