Bus Duct Design Calculation at the premises of M/s.

Continuous current : 1600 Amps

Short Circuit current : 32000 Amps
Location : Indoor, well ventilated
Ambient temperature : 35C
Permissible temperature rise on steady state thermal condition : 40C
Permissible temperature rise on short circuit condition : 100C
Initial temperature to be taken for short circuit condition : 70C
Duration of fault : 1 Sec
Materials for buses : Aluminium Alloy
: INDAL D50S WP
Allowable tensile stress on Aluminium bus bar : 1025Kg/Cm
Young's modulus of Aluminium : E:0.67 x 10 6Kg/cm
Temprature coefficient of resistance at 20C for Aluminium : 0.0036
Supports for buses : SMC
Allowable shear stress on SMC : 55.5Kg /Cm
Suggested size :
Bus size : 2 runs of 152.4 x 6.35mm
for phases and 1 run of
152.4 x 6.35mm for neutral
Enclosure size : 600 x 300mm
Center to center distance between buses : 107.3mm
Clearance between buses and enclosure : 150mm
Size of SMC supports : 70 x 20mm
Number of supports at a location : 2 Nos (One at top and other at bottom)
Spacing between supports : 500mm

A. Steady state thermal condition

Current rating of 2 runs of 152.4 x 6.35mm buses of

INDAL D50S-WP to 50C temperature rise over ambient
temperature of 35C (table -6) : 2860 Amps
Derating factor to be applied to materila (table -7) : 0.94
Derating factor to be applied for limiting temperature rise
to 40C over ambient temperature (table -7) : 0.88
Conductor area (2 x3 phase + 1 neutrals = 7) : 152.4 x 6.35 x 7
: 6774.18mm
Enclosure area : 600 x 300
Conductor area/Enclosure area : 0.03 = 3%
Enclosure factor to be applied (Table 5) : 0.75

Prooximity effect : Negligible

Actual current rating of proposed buses : 2860 x 0.94 x 0.88 x 0.75
: 1774Amps
Hence adequate

B. Short circuit condition

Temperature rise in C of

conductor for 1 Sec fault duration=T K x (I/A) (1+ ) x 10- :

Where K = 1.166 for Aluminium
A = Area of cross section of coductor in Sq.mm.
I = Fault current = 32,000Amps
= Temperature coefficient of resistance at 20C = 0.0036
= Initial temperature at which fault occurs: 70C
T = 1.166 x 32,000 x (1 +0.0036 x 70) x 10-
A
Permissible temperature rise is 100C
The minimum area of cross section of conductors shall be
1.166 x 32,000x (1 + 0.0036 x 70) 10-
A = = 1222mm2
100
Proposed buses have more sectional area. So adquate

C. Stress on bus bars

Electromagnetic force on short circuit, FM: 16 x 1 x 10-4 x K/S = 244.45mm
Where I = Fault current = 32,000Amps
S = Center to center spacing between buses = 107.3mm
(Space between runs of buses is 6.35mm)
K = Shape factor. This shall be obtained from Fig 8.6 in J&P
Switchgear book
Total thickness of conductor (a) = 6.35mm x 7 44.45mm
Width of conductor (b) = 152.4mm
Ratio, a/b = 44.45/152.4 0.29
.
.. s-a = 107.3 -44.45 = 0.3192786386
a+b 44.45 + 152.4

FM = 16 x 32,000 x 10-4 x 0.32

107.3 = 4886 N/m = 4.9Kg/cm

Force per bus bar = W = FM/No. of runs = 4.9/2 = 2.45Kg/cm

Max. bending moment M = W x L

8
(where L is distance between supports in Cm)
= 2.45 x 50 = 750Kg cms
8

Modulus of section Z = I
Y
Were I = bd = Y = d = So Z = bd2
12 2 6

Where 'b" is the width of conductor = 152.4mm = 15.24cm

d = thickness of conductor = 6.35mm = 0.635cm

bd = 15.24 x 0.635 = 1.024cm

6 6

Actual fibre force F = M = 750 = 732.42 Kg/Cm2

z 1.024

This is less than allowable stress on Aluminium, 1025Kg/Cm2. So safe

D. Spacing of supports
Support reaction = FM x L
= 6.6 x 40 = 264Kgs
Force on one support = 264/2 = 132Kgs
Assuming shear failure mode, area
resisting shear force = 2 x (1.58 + 3 x 0.72)
= 7.5cm
Shear Stress = 132/7.5 = 17.6Kg/cm
Allowable stress is 55.5Kg/cm2. So spacing is adequate

E. Max. deflecgion of conductor

S = 5WL 4

S = Max. deflection in cms

W = Force / Busbar = 3.3Kg/Cm
E = Yourn's modulus for aluminium = 0.67 x 10 6 Kg/cm
I = Moment of inertia = bd = 15.24x 0.635 = 0.325cm4
12 12
 L = Distance between supports = 50cm

Max. deflection S = 5 x 3.3 x 50 4 = 0.913Cm = 9.13mm

384 x 0.67 x 10 6 x0.325

200mm space is provided between buses, So safe
Proposed busduct is adequate in all repsects