OVER HEAD BUS BAR

DESIGN FOR SUBSTATION

Engr. Muhammad Rashid Iqbal
Deputy Manager (Substation Design)
m.rashid@ntdc.com.pk
 Learning Objective

 After taking this course you should,

 Know the materials used for electrical substation bus;
 Be able to explain the different types of rigid bus;
 Understand the ampacity of the various bus materials;
 Understand the proper connections for the various types of bus;
 Know how to design a rigid bus;
 Know the wind and ice loading criteria;
 Be able to calculate bus deflections;
 Understand how to space couplers on bus;
Rigid Conductors
 Flat bars
o Flat bars can be utilized for outdoor substation buses and are particularly suitable
since they can be easily bent and joined.
o Flat bars are usually limited to use at lower voltages because of corona.
 The structural shape
o conductors that have been used in outdoor substation construction consist primarily
of angle and channel types.
o To increase ampacity, two angles or channels can be used. Special fittings are usually
required for these configurations.
o The positioning and grouping of structural shapes have limitations similar to those of
flat bars.
o The rigidity of both angle and channel shapes is somewhat higher than for flat bars of
the same ampacity. Consequently, support spacing can usually be increased.
 Rigid Conductors
 Square and round tubular
o These shapes are considerably more rigid than either flat bars or structural
shapes of the same ampacity and permit longer spans.
o The flat surfaces of square tubes provide convenient connection and support
points.
o To facilitate heat dissipation, ventilation holes are sometimes provided in the
square tubes.
o Round tubular conductors are the most popular shape used in outdoor
substation construction.
o The round shape is very efficient structurally and electrically and minimizes
corona at higher voltages.
o The special fittings required for connecting, terminating, and supporting round
tubular conductors are widely available.
 Aluminum conductors alloys and tempers
o Aluminum conductors are available in a variety of alloys and tempers with different
conductor conductivities and strengths.
o Round tubular conductors are usually specified as either 6061-T6 or 6063-T6 alloy.
o The 6063-T6 alloy has a conductivity approximately 23 percent higher and a
minimum yield strength approximately 29 percent lower than the 6061-T6 alloy.
o Alloy 6063-T6 has been widely used for outdoor high voltage substation buses
because of its excellent mechanical, electrical properties, availability and economy
o The 6063-T6 alloy can carry higher currents but may require shorter support
intervals.
o The Schedule 80 sizes have wall thicknesses approximately 40 percent thicker than
the Schedule 40 sizes, resulting in lower deflections for equal span lengths.
o Alloy 6106-T61 is frequently utilized for flat bars, structural shapes, and square
tubes. Where high strength is desirable and conductivity requirements are lower,
alloy 6061-T6 bus is used
Bending of tubular conductor

 The most important factors governing the bending of bus conductors are:
(I) the ductility of the conductor, (2) the size and shape of the conductor,
(3) the method of bending, and (4) the bending equipment used
Flexible Conductors
o Most flexible conductors used in substation construction consist of all copper, all
aluminum, or aluminum with steel reinforcing (ACSR).
o The conductor type selected for a particular application is usually based on the
span length, tension and tolerable sag, and cost.
o For long spans, large supporting structures will be required. The size and cost of
these structures may depend on the conductor type and should be considered
during the selection process.
o Flexible conductors are available in many sizes. Size selection is based on
ampacity, strength, weight, and diameter.
o Conductor diameter becomes increasingly important at higher voltages where
corona can be a problem.
Select conductor type

There are many types of conductors that may be used. Factors considered include
the following:
o a) Ampacity
o b) Corona
o c) Mechanical strength and deflection
o d) Seismic withstand
o e) Cost
Conductor Ampacity

o The ampacity of bare conductors is based on a number of factors, including the

conductor material, proximity of the conductors, climatic conditions, conductor
temperature rise, emissivity, and altitude.
o The current distribution of closely spaced conductors is affected by their mutual
inductance in accordance with the proximity effect.
o The additional losses attributed to this effect can usually be neglected if
conductor spacing is 18 inches or greater
Conductor Ampacity
o Climatic conditions have a great effect on conductor ampacity. Ampacities are
usually determined based on ambient temperatures of 40C. For prolonged
ambient temperatures above this value, ampacities are usually reduced.
o Wind tends to reduce the temperature of outdoor bare conductors. An assumed
steady wind may be reasonable in many areas.
o The sun’s radiation can cause the temperature of bare conductors to increase,
which results in lower ampacities and should be considered in predominately
sunny locations.
o Conductor temperature rise is the temperature increase above ambient at which
the conductor is operating.
o To prevent excessive surface oxidation and possible damage from annealing, the
temperature rise is usually limited to 30C for a total maximum conductor
temperature of 70C
Conductor Ampacity

o The conductor surface emissivity has an effect on conductor ampacity.

o For aluminum conductors, emissivity is usually taken as 0.5 and for copper
conductors 0.8.
o Both of these values are for heavily weathered conductor surfaces.
o The ampacity is usually higher for greater emissivity.
o Equipment that depends on air for its cooling medium will have a higher
temperature rise when operated at higher altitudes than when operating at
lower altitudes.
o For altitudes in excess of 3,300 feet, the correction factors listed in Table 1 should
be applied.
Altitude Correction Factors Current

o Equipment that depends on air for its cooling medium will have a higher
temperature rise when operated at higher altitudes than when operating at
lower altitudes.
o For altitudes in excess of 3,300 feet, the correction factors listed in Table 1 should
be applied.
Altitude Correction Factors Current

Table 1 Altitude Correction Factors Current

Altitude (Feet) Current Rating Ambient Temperatures
3,300 1.00 1.00
4,000 0.995 0.992
5,000 0.99 0.980
6,000 0.985 0.968
7,000 0.98 0.956
8,000 0.97 0.944
9,000 0.965 0.932
10,000 0.96 0.920
12,000 0.95 0.896
14,000 0.935 0.872
Altitude Correction example

o Consider a conductor with an ampacity of 1,000 amperes in a 40C ambient

temperature with a 30C temperature rise at an altitude of 3,300 feet.
o If this conductor is to be used at a higher altitude, the ampacity has to be
corrected. At 14,000 feet, this conductor will have an ampacity of 1000 x 0.935 =
935 amperes in an ambient temperature of 40C with a 30C temperature rise.
o The conductor may be operated at 1000 amperes at 14,000 feet, provided the
ambient temperature does not exceed 40C x 0.874 = 34.96C and the temperature
rise does not exceed 30C.
Design considerations

Additional considerations must be made to finalize the design. These include the
following items:
o a) Clearances
o b) Transitions between different bus type and/or heights
o c) Bus to equipment connections
o d) Grade changes. A large station may have a grade change. To minimize bus
bends, the footing height may be varied to maintain a constant bus elevation.
Footing elevation changes can compensate for a certain amount of elevation
change, and beyond this, bus transitions will be required.
o e) Access to the equipment and bus during construction and maintenance.
Rigid Bus Design

o Select the material and size of the bus conductors based on continuous current
requirements
o In higher voltage systems with longer bus spans, the structural capabilities of the
conductors may be the factor that determines the conductor material and size
o Using Tables 2 and 3, determine the bus conductor centerline-to-centerline
spacing
Table 2 Substation Clearances
Table 3
Rigid Bus Design (Short circuit force on conductor)

Calculate the maximum short circuit forces the bus has to withstand

FSC = Maximum short-circuit force on center conductor

KSC = Short-circuit force reduction factor (0.5 to 1.0; 0.67 recommended)
i = RMS value of three-phase symmetrical short-circuit current, in amperes
D = Centerline-to-centerline spacing of bus conductors in inches
Loads on bus bar
ICE LOADING ON CONDUCTOR

The ice loading can be determined using,

o WI = Ice loading, in pounds per foot

o d1 = Outside diameter of conductor with ice, in inches (determine ice
thickness from Table 4)
o d2 = Outside diameter of conductor without ice, in inches
WIND LOADING ON CONDUCTOR

o The wind loading can be determined using,

o FW = Wind loading, in pounds per foot

o CD = Drag coefficient (See Figure 1)
o PW = Wind pressure, in pounds per foot2 (from Table 4)
o d1 = Outside diameter of conductor with ice, in inches
o The total bus conductor loading can be determined using
Figure 1 shows the drag coefficients for
various structural shapes
The total bus conductor loading

The total bus conductor loading can be determined using,

o FT = Total bus conductor loading, in pounds per foot

o FSC = Maximum short-circuit force, in pounds per foot
o FW = Wind loading, in pounds per foot
o WC = Conductor weight, in pounds per foot (if damping cables are
used to control conductor vibration, add the cable weight to the
conductor weight)
o WI = Ice loading, in pounds per foot
The total bus conductor loading

o The preceding equation applies maximum wind and maximum ice at the
same time
o NESC and ANSI/IEEE Std. 605 apply these forces individually, which
reduces FT
o Engineering judgment based on site conditions and design loads should
determine the maximum loading conditions of the bus
Maximum bus span or support spacing

Maximum bus support spacing can be determined using,

o LM = Maximum bus support spacing, in feet

o KSE = Multiplying factor from Table 5
o FB = Maximum desirable fiber stress of conductor, in pounds per inch2
Maximum bus span or support spacing

For round tubular conductors of:

o Copper, FB = 20,000 lb/in2*
o 6061-T6 aluminum alloy, FB = 28,000 lb/in2*
o 6063-T6 aluminum alloy, FB = 20,000 lb/in2*
*Includes a safety factor of 1.25.
o S = Section modulus of conductor, in inches3
o FT = Total bus conductor loading, in pounds per foot
Maximum bus span or support spacing
VERTICAL CONDUCTOR DEFLECTION(SAG)
Calculate the maximum vertical conductor deflection using,

o y = Maximum vertical conductor deflection, in inches.*

o KDE = Multiplying factor from Table 5
o WC = Conductor weight, in pounds per foot (if damping cables are used to
control conductor vibration, add the cable weight to the conductor
weight)
o WI = Ice loading, in pounds per foot
o L = Bus support spacing, in feet
o E = Modulus of elasticity, in pounds per inch2
o I = Moment of inertia, in (inches4)
Limit the Maximum vertical conductor
deflection value
o *Note. Limit the Maximum vertical conductor deflection value to 1/200 of
the span length
o If the value calculated is greater than 1/200 of the span length, select a
conductor with a larger diameter or reduce the span length
o Recalculate as required
Minimum required support insulator cantilever
strength
Determine the minimum required support insulator cantilever
strength using,

o WS = Minimum insulator cantilever strength, in pounds

o FSC = Maximum short-circuit force, in pounds per foot
o FW = Wind loading, in pounds per foot
o LS = One half of the sum of the lengths of the two adjacent
conductor spans, in feet
Minimum required support insulator
cantilever strength
o Note: This equation includes an insulator safety factor of 2.5. This
results in the insulator’s working load being equal to 40 percent of
the insulator’s rated cantilever strength.
o Select support insulators from manufacturers’ data with cantilever
strength ratings equal to or greater than WS.
o If sufficiently high ratings are not available, it will be necessary to
modify the bus design.
o This can be done by increasing the centerline-to-centerline
conductor spacing to reduce the short-circuit forces or by
decreasing the bus span lengths
Thermal expansion of conductors

The amount of conductor thermal expansion can be calculated using,

An example of a typical bus system is diagrammed
in Figure 2
It is usually desirable to limit the length of sections of continuous
buses to 100 feet or less to limit the amount of conductor expansion
in each section
Table 6 lists the ideal locations for conductor
couplers for continuous conductors
Aeolian conductor vibration
o When steady low-velocity transverse winds striking the conductor and
causing it to vibrate. When the frequency of the driving force (wind) is
approximately equal to the natural frequency of the bus span, resonance
occurs. The resulting vibrations can cause insulator damage
o Vibrations will occur in almost all bus spans independently of the
conductor material, diameter, or length
o In spans longer than about 20 feet, methods for vibration damping should
be considered
o The first and most widely used method consists of installing scrap cables
in the horizontal buses
o The second method used to dampen vibrations consists of installing
internal or external prefabricated bus dampers on the bus conductors.
Usually, one damper is installed in each bus span to control the vibrations.
Location and installation should be in accordance with the manufacturer’s
instructions
CASE STUDY (Rigid bus design)
Method -I
Rigid Bus Design Example
Design a three-phase rigid bus with the following characteristics:
o Total bus length: 150 feet, assuming four equal spans of 37.5 ft
o Voltage: 161 kV
o BIL: 750 kV
o Insulator type: post
o Continuous current rating: 1800 amperes
o Short-circuit current: 24,000 RMS symmetrical amperes
o Altitude: 1,000 ft
o NESC loading: heavy
o Disconnect switch connected to one end of bus
o External prefabricated dampers to control conductor vibration
Rigid Bus Design Example
Design a three-phase rigid bus with the following characteristics:
o Total bus length: 45.72 meters (150 feet), assuming four equal spans of
11.43 m(37.5 ft)
o Voltage: 161 kV
o BIL: 750 kV
o Insulator type: post
o Continuous current rating: 1800 amperes
o Short-circuit current: 24,000 rms symmetrical amperes
o Altitude: 304.8 m (1000 ft)
o NESC loading: heavy
o Disconnect switch connected to one end of bus
o External prefabricated dampers to control conductor vibration
 Step1.
Select the material and size of the bus conductors
o Based on the continuous current requirements, 3 in. IPS, schedule 40 6063-
T6 aluminum alloy (1,890 amperes) is selected with the following properties:
o WC (weight) = 2.62 lb/ft*; see Table 7
o d2 (outside diameter) = 3.50 inches; see Table 7
o I (moment of inertia) = 3.017 in4; see Table 7
o E (modulus of elasticity) = 10 x 106 lb/in2)
o S (section modulus) = 1.72 in3 see Table 7
o FB (maximum allowable fiber stress) = 20,000 lb/in2
o * If damping cables are to be used to control conductor vibration, the cable
weight has to be added to the conductor weight. In this example, external
prefabricated dampers will be used for vibration control.
 Step1.
Select the material and size of the bus conductors
o Based on the continuous current requirements, 7.6 cm (3 in.) IPS, schedule
40 6063-T6 aluminum alloy (1890 amperes) is selected with the following
properties:
o WC (weight) = 38.2 N/m (2.62 lb/ft)*; see Table 4-14
o d2 (outside diameter) = 8.89 centimeters (3.50 inches); see Table 4-14
o I (moment of inertia) = 125.6 cm4 (3.017 in4); see Table 4-14
o E (modulus of elasticity) = 6.9 x 107 kPa (10 x 106 lb/in2)
o S (section modulus) = 28.2 cm3 (1.72 in3); see Table 4-14
o FB (maximum allowable fiber stress) = 1.38 x 105 kPa (20,000 lb/in2)
o * If damping cables are to be used to control conductor vibration, the cable
weight has to be added to the conductor weight. In this example, external
prefabricated dampers will be used for vibration control
 Step 2. Spacing
o Determine the bus conductor centerline-to-centerline spacing from
Table 2
o D (bus centerline-to-centerline spacing) = 108 in
 Step 2. Spacing
o Determine the bus conductor centerline-to-centerline spacing from
Table 4-7:
o D (bus centerline-to-centerline spacing) = 274 cm (108 in.)
Step 3. Short Circuit Forces

Short Circuit Forces:

Step 3. Short Circuit Forces
Short Circuit Forces: lb/ft Short Circuit Forces: N/m
Step 4. Loading: Determine the total bus conductor
loading
o From Table 4, Radial thickness of ice: 0.50 in. Horizontal wind
pressure: 4.0 lb/ft2.
Step 4. Loading: Determine the total bus conductor loading
From Table 4-9, Radial thickness of ice: 1.27 cm (0.50 in.)
Horizontal wind pressure: 191.5 Pa (4.0 lb/ft2)
Step 5. Calculate the maximum bus support spacing

o Four equal spans of 37.5 feet were assumed. From Table 5, KSE =
0.88 for three or more equal spans

o The assumed spacing of 37.5 ft is structurally permissible for the

conductors
Step 5. Calculate the maximum bus support spacing

o Four equal spans of 11.43 meters (37.5 feet) were assumed

o From Table 4-12, KSM = 0.096 (KSE = 0.88) for three or more equal spans

o The assumed spacing of 11.43 meters (37.5 ft) is structurally permissible for
the conductors
Step 6. Calculate the maximum vertical conductor deflection

o Four equal spans of 37.5 feet were assumed. From Table 5, KDE =
11.9 for three or more equal spans

o Maximum permissible deflection is 1/200 of the span length:

Step 6. Calculate the maximum vertical conductor deflection

o Since the calculated deflection is greater than the maximum permissible

deflection, the design has to be modified. The span length will be reduced
to five equal spans of 30 feet each. The maximum vertical deflection is
then recalculated:

o Maximum permissible deflection is:

o Since the calculated value with 30 feet support spacing is less than the
maximum permissible deflection, this support spacing is adequate.
Step 6. Calculate the maximum vertical conductor
deflection
Step 6. Calculate the maximum vertical conductor deflection
o Since the calculated deflection is greater than the maximum permissible
deflection, the design has to be modified. The span length will be reduced to five
equal spans of 9.14 meters (30 feet) each.
o The maximum vertical deflection is then recalculated:

o Maximum permissible deflection is:

o Since the calculated value with 9.14 m (30 ft) support spacing is less than the
maximum permissible deflection, this support spacing is adequate.
Step 7.
Determine the minimum required support insulator cantilever strength

o Therefore, we will need to select a post insulator with 1,109 pounds or

greater cantilever strength
Step 7.
Determine the minimum required support insulator cantilever strength

o From Table 4-5, select Technical Reference Number 291 for 5338 newton
(1200 pounds) cantilever strength post type insulators.
Step 8. Provide for conductor expansion
o Assuming a total conductor temperature variation of 50C, the total
conductor expansion is:
Step 8. Provide for conductor expansion

o Assuming a total conductor temperature variation of 50oC (90oF), the total

conductor expansion is:
Step 9. Locate conductor couplers
o From Table 7, the ideal coupler locations for the five-span bus of 30-foot
spans measured to the right from the left-most support are as follows:
 Step 9. Locate conductor couplers
o From Table 4-13, the ideal coupler locations for the five-span bus of 9.14-meter (30-
foot) spans measured to the right from the left-most support are as follows:

o These locations are illustrated in Figure 4-25.

o These locations are illustrated in Figure 4. Assuming that the bus
conductor is available in 40-foot lengths, the couplers should be
positioned at points 2, 4, 6, and 8.
o The conductor lengths are cut as required to position the couplers at
these approximate locations.

o Since the spans are fairly long, damaging vibrations may occur.
Consequently, a means for controlling the vibrations should be provided.
o Prefabricated dampers can be attached to the buses or scrap cables can
be installed in the buses. If cables are used, the cable weight has to be
added to the conductor weight for the bus calculations
o Assuming that the bus conductor is available in12.19-meter (40-foot) lengths, the
couplers should be positioned at points 2, 4, 6, and 8
o The conductor lengths are cut as required to position the couplers at these
approximate locations

Figure 4-25: Bus Configuration for Example

Legend:
SF = Slip-fit bus support
F = Fixed bus support
EX = Expansion terminal
 Aeolian Vibration:.

Aeolian Vibration:
o Since the spans are fairly long, damaging vibrations may occur
o Consequently, a means for controlling the vibrations should be
provided.
o Prefabricated dampers can be attached to the buses or scrap cables
can be installed in the buses.
o If cables are used, the cable weight has to be added to the
conductor weight for the bus calculations.
CASE STUDY (Rigid bus design)
IEEE Method-II
Procedure for bus bar design IEEE Method
o Determine bus conductor size required for both maximum normal load and
short circuit current (Clause 8 and Annex C)
o Determine maximum corona on the bus and equipment (Clause 9 and Annex
D)
o Determine maximum forces on the structures (Clause 11)
o Determine maximum span length of the bus based on vertical deflection limit
and fiber stress (12.1 and12.2)
o Determine maximum required insulator rating (12.3 and 12.4)
o Determine thermal expansion requirements (11.4)
o Determine bus vibration and damping requirements (12.5, 12.6, and 12.7)
 Rigid Bus Design Example
Table H.1—Design parameters
 Parameters Values
o Maximum load 180 MVA, 1506 A
o Maximum fault current 20 kA
o Maximum operating voltage 69 kV
o Fault clearing time 0.25 s (15 cycles)
o Phase spacing 2.44 m (8 ft)
o Operating bus temperature 90 °C (194 ° °F)
o Maximum allowable temperature 250 °C (482 ° °F)
o Minimum/maximum ambient temperature 0 °C/ 40 °C (32 °F/ 104 °F)
o Maximum wind speed 144 km/h (90 mph)
o High wind speed with ice 64 km/h (40 mph)
o Maximum anticipated icing condition 6.35 mm (0.25 in)
o Latitude/longtitude 30°N, 112°W
o Elevation 366 m (1200 ft)
o Seismic activity Insignificant
o Atmospheric condition Clear
 Step1.
Select the material and size of the bus conductors
o Conductors will be 6106-T6 (55% IACS) aluminum tube for rigid bus work and
1350-H19 (61% IACS) all aluminum conductor (AAC) for equipment connections
o The size for each will be selected for both normal and short-circuit conditions
o The full load current is 1506 A. A 20% allowance will be made for future growth
and overloading. The design load current then becomes 1807 A
Minimum size for load current (Refer to 8.1 and Annex C.)
o The conductors will be sized for a load current of 1807 A. The maximum
continuous conductor temperature will be 90 °C as recommended in 8.2.1. (IEEE
Std C37.30-1997). The designer needs to verify that the maximum temperature is
appropriate for the equipment being used in the substation.
o Ampacity tables may be used to select the conductor size. However, tables may
not be available to match the design parameters.
o Initial sizes will be selected from tables, and then values for the design
parameters will be calculated
Select the material and size of the bus conductors
Rigid bus
o From Table B.4, with sun, 0.5 emissivity, and a temperature rise of 50 °C, a 64
mm (2.5 in) SPS schedule 40 aluminum tube provides an ampacity of 1876 A.
o This conductor may be selected as a trial size, and the ampacity will be
confirmed for the design parameters using Equation (C.1)

o qC Convective heat loss

o qr Radiation heat loss
o qS Solar heat gain
o R DC resistance at operating temperature
o F Skin effect coefficient. Normally included in the conductor resistance as
published by the Aluminum Electrical Conductor Handbook [B1].
 Minimum size for short circuit current
o The short circuit current rating of these conductors should be verified to
ensure that they are capable of carrying the available short circuit current
(20 kA) for the time specified (0.25 s).
o Equation (3) in the guide, along with the variables in Table H.14, will be used
to determine the maximum current that the conductors can carry for 0.25 s
and a maximum conductor temperature of 250 °C:

o To calculate the cross-sectional area of 64 mm (2.5 in) SPS, schedule 40 bus,

refer to Table B.4 to obtain outside diameter (D) and wall thickness (t):
 Table H.14—Variables for conductor short circuit
current calculations
Variable Description Value

C Constant 2.232 × 10-4 for metric units with A in mm2

Isc Short-circuit current
G Conductivity, per Table 2
t Fault clearing time
20 kA
53% for 6063 T6 aluminum (rigid bus), 40%
for 6063 T6 aluminum (rigid bus)&
61% for 1350-H19 (flexible conductor)
0.25 s

Tf Maximum conductor temperature 250 °C

Ti Initial conductor temperature 90 °C
Ac (rigid)
Conductor area, tube 1099 mm2
Ac
(flexible) Conductor area, flexible bus
483.4 mm2
Minimum size for short circuit current
Allowable short circuit current for rigid bus:

Allowable short circuit current for one flexible conductor:

o For two flexible conductors, the allowable short circuit current will be twice
the value above = 182 kA.
o Based on the above calculations, both the rigid bus and flexible conductors
are adequately rated for the short circuit current of 20 kA.
STEP-2. Determine maximum corona on the bus and
equipment (Clause 9 and Annex D)
For rigid conductor
o Corona cannot be eliminated, but it can be controlled to acceptable levels.
o The goal is that the corona is below the allowable voltage gradient. Refer to Clause 9 and Annex D.
o First we need to evaluate the corona onset gradient given by Equation (D.1):

where
o Ec is the corona onset gradient, kV/cm
o E0 is an empirical constant
o C is an empirical constant
o m is the conductor irregularity factor
o Da is the relative air density
o rc is the conductor outside radius, cm
o Peek found E0 = 30 kV/cm (peak value) or 21.1 kV/cm (rms value) and C = 0.301 cm–1.
STEP-2. Determine maximum corona on the bus
and equipment (Clause 9 and Annex D)
For rigid conductor
o Using the variables of table H.15 given below
 Table H.15—Variables for corona onset gradient Ec
calculation
Variable Description Value
m Air density factor, use worst case of 0.6–0.85 range 0.85
suggested in D.1.1
Eo Empirical constant per D.1.1 21.1 kV/cm
Da Relative air density per Equation (D.2), Equation (D.3) and 0.917
calculated below
C Empirical constant 0.301 cm-1
rc Conductor outside radius (equivalent radius for a bundle 3.65 cm for rigid bus
of n sub conductors) 3.81 cm for flexible
conductor
as calculated below
T Ambient air temperature 40 °C
To Air temperature used in determining constants Eo and C 25 °C
and factor m
A Altitude 0.366 km
For flexible conductor
Determine maximum corona on the bus and
equipment (Clause 9 and Annex D)
o For flexible conductor, we first need to calculate the equivalent single-
conductor radius of bundle sub conductors, using Equation (D.11) with n =
2 (2 flexible conductors):
Rigid bus conductor voltage gradient
The maximum voltage gradient is evaluated using Equation (D.6), Equation (D.7),
and Equation (D.8) using the data given in Table H.16.
Table H.16—Variables for voltage gradient calculations for rigid bus
Variable Description Value
he Conductor height above ground cm [in] 366 cm

d Bus conductor diameter cm [in] 7.30 cm

D Phase-to-phase spacing 244 cm
V1 Phase-to-ground voltage multiplied by 1.1 43.82 kV
(V1 is 110% of nominal operating line-to-ground voltage.)

Equivalent distance from center of conductor to ground per Equation (D.8):

Rigid bus conductor voltage gradient
 Three-phase conductor
The maximum voltage gradient for rigid bus

o Average voltage gradient per Equation (D.6):

o Maximum voltage gradient per Equation (D.7):

o For satisfactory operation, Em < Ec. The 64 mm (2.5 in) SPS, schedule 40
aluminum tube meets this criteria and is acceptable.
Flexible bus conductor voltage gradient
The maximum voltage gradient is evaluated using Equation (D.12) and Equation
(D.13), and the data given in Table H.17.
o Average voltage Ea gradient per Equation (D.12):

o Maximum voltage gradient per Equation (D.13):

For satisfactory operation, Em < Ec. The 954 kcmil AAC meets this criteria and is
acceptable.
 Flexible bus conductor voltage gradient
o n is the number of sub conductors in bundle
o g is equal to 1 for bundle of 1, 2, or 3 sub conductors and is equal to 1.12 for bundle
of 4 sub conductors
o d is the conductor diameter, cm [in]
o s is the distance between conductors, cm [in]
o r is the conductor radius, cm [in] and is given by d/2
o re is the equivalent single-conductor radius of bundle sub conductors, cm [in], is
given by:
Table H.17—Variables for voltage gradient calculations
for flexible conductor bundle
Variable Description Value

he Equivalent height to ground (calculated above) 115.74 cm

d Bus conductor diameter 2.86 cm

r Bus conductor radius 1.43 cm
D Phase-to-phase spacing 244 cm
V1 Phase-to-ground voltage multiplied by 1.1 43.82 kV

re Equivalent single-conductor radius of bundle sub 3.812 cm

conductors (calculated above)
 Step-3 Rigid bus loads
Conductor weight
o Based on Equation (5) and the data in Table H.18, the unit weight of the
rigid bus is given by:
o Fc =π wc tc (Do − tc )=π × 26500×0.0052×(0.073− 0.0052) = 29.4 N/m
Table H.18—Variables for rigid bus conductor force

Variable Description Value

wc Specific weight of aluminum(N/m3) [lbf/in3], 26 500 N/m3
(for aluminum wc = 26 500 N/m3 [0.0977 lbf/in3])
tc Conductor wall thickness (m) [in], see Table B.4 0.0052 m
Do Conductor outside diameter (m) [in], see Table B.4 0.073 m
Step-3 Rigid bus loads
Ice load
o Using Equation (6) and the data in Table H.19, the ice unit weight is given
by:

Table H.19—Variables for ice force on rigid bus

Variable Description Value
wi Ice weight, (8820 N/m3) [0.0330 lbf/in3] 8820 N/m3

ri Equivalent uniform radial ice thickness 0.00635 m

Do Conductor outside diameter, see Table B.4 0.073 m

Step-3 Rigid bus loads
Wind loads
o Extreme wind generally results in higher loads than high wind with ice.
Both will be calculated to determine which is larger
o Here the extreme wind loading without ice will be calculated using
Equation (8) and the data in Table H.20:
 Step-3 Rigid bus loads
Wind loads
Table H.20—Variables for extreme wind load (without ice)
Variable Description Value

C Constant, for metric units 0.613

(SI: 0.613, British: 2.132 × 10-4)
V Extreme wind velocity, from Figure 14 14 40 m/s (144km/h)
Do Conductor outside diameter 0.073 m
Cf Force coefficient for rigid tubular bus per 11.2.3 1.0
KZ Height and exposure factor, Exposure B 0.57
from Table 7
Gf Gust response factor, per 11.2.5 ( in rigid bus 0.85
structures for all exposure categories)
I Importance factor for structure, per 11.2.6 1.15
Step-3 Rigid bus loads (Wind loads)
o Here the high wind loading with ice will be calculated using Equation (9)
and the data in Table H.21:
Table H.21—Variables for high wind with ice
Variable Description Value
C Constant, for metric units 0.613
(SI: 0.613, British: 2.132 × 10-4)
VI Extreme wind velocity, from Figure 8 17.8 m/s (64 km/h)
Do Conductor outside diameter 0.073 m
ri Equivalent uniform radial thickness of ice 0.00635 m
Cf Force coefficient for rigid tubular bus per 1.0
11.2.3
KZ Height and exposure factor, Exposure B 0.7
from Table 7
Gf Gust response factor, per 11.2.5 0.85
 Step-3 Rigid bus loads(Short circuit load)
o The short circuit force for infinitely long parallel conductors is calculated using Equation
(14) and Equation (16),which provides corrections to account for the momentary peak
factor effect and mounting structure flexibility, using the data in Table H.22:
 Table H.22—Variables for short-circuit calculations

Variable Description Value

ISC Short-circuit current 20 kA

D Phase spacing 2.44 m
Df Half cycle decrement factor from Equation (18) and 0.927
Equation (19) with X/R = 20, table14
Kf Mounting structure flexibility factor, from Figure 20 for a 1
bus height of 4.27 m (14 ft) and steel structures (Type B)
Γ Constant based on type of fault and conductor location, 0.866
Step-3 Rigid bus loads
 Total gravitational force
o The gravitational force will be evaluated without ice & no damping material is
used with the conductor
o The gravitational force is therefore equal to the conductor weight:
i.e 1pound/ft= 14.5939029 N / m (2.004* 14.6=29.4)

 Total force
o The total force is given by the vector sum of the vertical and horizontal forces,
as per Equation (78).
o We will consider here that short circuit is concurrent with wind and will
evaluate the cases without and with ice.
o The total force for extreme wind with no ice, short circuit, and conductor
weight is given by:
Total force

o The total force for high wind with ice, short circuit, and conductor weight
is given by:

o The higher loading occurs for extreme wind with no ice, FT1.
 Step-4 Allowable span
 Allowable span based on deflection limit
o The deflection of a span with pinned-pinned end conditions will be calculated without
any damping material.
o The recommended allowable deflection of 1:150 (0.67 %) will be used. i.e. the ratio
of conductor deflection to span length or the conductor diameter (0.5 to 1times the
diameter)
o The ice weight is usually not considered for vertical deflection. However, if the vertical
deflection during icing conditions is important, then ice weight should be considered
o The all allowable span is given by Equation (72), using the data in Table H.23:

o The total gravitational force on a conductor is the sum of the weights of the
conductor(FC), damping material(FD), and ice(FI, equation[6]) if the latter is of concern
in the allowable deflection
FG = Fc + FD + FI
Table H.23—Variables for allowable span calculations
based on deflection limit
Variable Description Value
η Allowable deflection as a fraction of span length 0.0067 (1/150)
(recommended allowable deflection of 1:150 (0.67 %))
E E Modulus of elasticity for aluminum 68.9 × 109 N/m2
J J Bending moment of inertia, per Equation (73), see 6.40 × 10-7 m4
calculation below
FG FG Gravitational force 29.4N/m
Do conductor outside diameter, m [in] as provided in table 0.073m
Di conductor inside diameter, m [in] as provided in table 0.0626m
 Allowable span based on fiber stress
o Fiber stress will be based on a single span with pinned-pinned end conditions
that provide a worst-case result
o The yield stress of 6061-T6 aluminium is 240 MPa (35 ksi) according to AWS
D1.2-2003 (see Clause 2)
o Welded couplers and connectors will be used. Welding reduces the allowable
stress to approximately 50% according to the Aluminum Design manual (see
Clause 2)
o The allowable yield stress is therefore 120 MPa
o Using Equation (79) and the data in Table H.24, the allowable span is given by:
Table H.24—Variables for allowable span calculations based
on fiber stress
Variable Description Value

J Bending moment of inertia (as calculate above) 6.42 × 10-7 m4

σ allowable Allowable stress of material accounting 120 MPa
for welds
FT Total force, per H.6.6 246.0 N/m
Do Conductor outside diameter 0.073 m

Maximum allowable span

o The maximum span will be the lesser of the lengths based on deflection and
fiber stress. For this example, the two values are 9.17 m and 8.27 m. The
maximum span is therefore 8.27 m, and we will round up this value to 8.3 m in
the following discussion
 Step-5 Vibration
Natural frequencies of rigid bus spans
o Since the end connections are never perfectly pinned-pinned or fixed-fixed, we will
evaluate the natural frequency based on these two sets of end conditions to get the
range of possible fundamental frequencies of a span. We will use the allowable span
calculated above of 8.3 m.
o The natural frequency is calculated using Equation (103) and the data in Table H.25.
For pinned-pinned conditions we have:

For fixed-fixed conditions we have:

 Step-5 Vibration
Table H.25—Variables for natural frequency calculations
Variable Description Value
K Constant based on bus end conditions 1.0 for pinned-pinned
and 1.51 for fixed-fixed
L Span length 8.3 m
E Modulus of elasticity 68.9 N/m2
J Bending moment of inertia (as calculated above) 6.40 × 10-7 m4
m Mass per unit length, see calculation below 3.00 kg/m
Wind-induced vibration
o Wind induced excitation frequency is calculated using Equation (100) and the data
in Table H.26. V here is not the maximum wind speed expected at the site, but the
speed expected under normal operation conditions.
o Since wind speeds below 8 km/h or above 72 km/h do not induce vibrations,
these will be used as lower and upper boundaries of the speed expected at the
site.
Step-5 Wind-induced vibration

o The upper frequency with the upper wind speed is given by:

o The lower frequency with the lower wind speed is given by:
Step-5 Vibration
Table H.26—Variables for wind-induced vibration calculations
Variable values
C 0.19 for a cylinder per Equation (100) description
V wind speed in m/s: Upper: 72 km/h = 20.00 m/s;
Lower: 8 km/h = 2.22 m/s
Do 0.073 m
o A conductor will vibrate if its natural frequency is in the vicinity of either
the wind frequency or that of the alternating current (2f).
o It is recommended that an allowance for variations be allowed. This is
accomplished by ensuring the ratio of the natural frequency to the
inducing frequency is not in the range 0.5 to , as given by Equation (101):

o Based on the excitation frequencies calculated above as well as the span

natural frequencies for both pinned-pinned and fixed-fixed conditions, we
can evaluate the worst combinations that could fall within the range to
avoid:
Step-5 Vibration
Pinned-pinned condition

o It is observed for the pinned-pinned conditions that the ratios are outside
the range to avoid, so wind-induced vibration is unlikely to occur
Fixed-fixed condition

o It is observed for the fixed-fixed conditions that the ratio using the lower
frequency of wind excitation is within the range to avoid, so wind-
induced vibration is likely to occur
Step-5 Vibration
Induced vibration from alternating current
o Vibration due to alternating current excitation will occur when fb > f per Equation
(102). Using the maximum possible value of fb for fixed-fixed conditions, and the
power frequency of 50 Hz, we have: 6.30<50
o So the bus should not be affected by vibrations from alternating current
excitation
Vibration attenuation requirements
o Based on this analysis, vibration dampers will be required due to wind-induced
vibration
o The use of either a damping cable or dampers is recommended
o Therefore, the calculations for allowable span may have to be reviewed if a
damping cable is used since this adds mass and therefore increases the weight by
unit length in the vertical direction
 Step-6 Thermal expansion
o The expansion of this section of bus will be calculated for an installation temperature of 0 °C
and the operating temperature of 90 °C, using the data in Table H.27.
o A length of 16.6 m will be used, which is the largest length for this example (two continuous
spans of 8.3 m). Using Equation (65):
Table H.27—Variables for thermal expansion calculations
Variable values
α 23.1 × 10-6 1/°C for aluminum per Table 17
Ti 0 °C, minimum normal temperature
Tf 90 °C, maximum normal temperature
Li 16.6 m, length of bus

o A 16.6 m section of bus will therefore have 34.5 mm of expansion over the minimum-to-
maximum temperature range
o Supports need to be selected to accommodate this movement, or a thermal expansion fitting
at one support is recommended
Step-7 Insulator selection
o A sample calculation will be done for a two-supports bus span. The designers will be
required to carry out the same calculations for all spans and to select insulators for the
entire substation based on the maximum force from them.
Trial insulator selection
o Refer to insulator tables from a manufacturer. Most insulators are assigned a Technical
Reference number, which all manufacturers can supply.
o The standard strength 350 kV BIL insulator is a TR-216 insulator with a rated cantilever
strength of 6.67 kN (1500 lbf).
Span force calculations
o Calculations will be done considering two continuous spans of 8.3 m with support
boundary conditions P-C-P as per Table 18
o The sample bus uses vertically mounted insulators to support horizontal rigid bus. The
total cantilever force on the mid insulator is calculated using Equation (89)
o In this example, only forces in the x direction (see Figure 31) will create cantilever forces
because provision is made for bus expansion so that no force will be generated due to
thermal effects
Span force calculations
o The formula to calculate the cantilever force, using extreme wind with no ice gives

o The wind force on the insulator is calculated per Equation (8) and constants determined
earlier in H.6.3:

o Incorporating Equation (83), Equation (84), and Equation (87), and the data in Table
H.28, gives:
 Table H.28—Variables for cantilever force calculations
variables parameters Value

FW1 Wind force on insulator calculated per calculation above 187.9 N/m
V Extreme wind velocity, from Figure 14 1440 m/s (144 km/h)
Di Effective insulator diameter 0.28 m
FW2 Wind force on the conductor per H.6.3 (Fw) 49.0 N/m
FSC Short-circuit force on the conductor per H.6.4 195.2 N/m
LE Effective length of conductor span for two 8.3 m continuous 10.4 m
spans with P-C-P conditions as per Table 18 (5 L/4)
HT Total height of the insulator column 0.762 m
Hf Height from the insulator top to the bus center line, 0.08 m
refer to bus support manufacturer for value
kW Load factor for wind forces 2.5
kSC Load factor for short-circuit current (the requirements of 12.3.4 1.0
have been met).
 Step-7 Insulator selection

o The required rated cantilever strength is 3.83 kN (calculated)

o The selected TR-216 insulator has a rated cantilever strength of 6.67 kN
o This selected insulator has acceptable cantilever strength
Table 18
Table 19 —Maximum vibration-free span length for tubular bus