DMRC Electrical Standards & Design Wing (Desdw) : Delhi Metro Rail Corporation Limited

DMRC Electrical Standards & Design Wing DMES-T/0021
SPECIFICATIONS FOR LT BUS BAR TRUNKING SYSTEM (BUS DUCT) – Draft-1

COMPACT SANDWICH TYPE 19th Jan 2015
DELHI METRO RAIL CORPORATION LIMITED
DMRC ELECTRICAL STANDARDS &

DESIGN WING (DESDW)
SPECIFICATION NO.
DMES- T/0021/ DMRC-E-TR-BUSDUCT-01
SPECIFICATIONS FOR LT BUS BAR TRUNKING

SYSTEM (BUS DUCT)– COMPACT SANDWICH TYPE
Issued on:
Date Stage
th
19 Jan 2015 Draft - 1
DELHI METRO RAIL CORPORATION LTD.

th
7 Floor, B-Wing, Metro Bhawan, Fire Brigade Lane,
Barakhamba Road, New Delhi –110 001
Page 1 of 10

Previous Record of specification
Stage Date
Draft -1 19/01/2015
Page 2 of 10

CONTENTS
1. DETAILED DESCRIPTION OF THE EQUIPMENT AND ITS APPLICATION IN DMRC –LT BUS BAR TRUNKING
SYSTEM (BUS DUCT) - COMPACT SANDWICH TYPE ................................................................................................ 4
2. GOVERNING SPECIFICATION.......................................................................................................................... 4
2.1 STANDARDS .....................................................................................................................................................4

2.2 ABBREVIATIONS ................................................................................................................................................5
3. TECHNICAL REQUIREMENTS .......................................................................................................................... 5
3.1 BUS BARS......................................................................................................................................................5

3.2 ENCLOSURE ..................................................................................................................................................6
3.3 FLANGED END BOX .......................................................................................................................................6
3.4 EXPANSION JOINTS.......................................................................................................................................6
4. ADDITIONAL REQUIREMENTS........................................................................................................................ 6
4.1 RISING MAIN PLUG-IN TAP-OFF BOXES -FEAUTURES ...................................................................................6

4.2 TERMINAL ARRANGEMENTS .................................................................................................................................7
5. SAFETY .......................................................................................................................................................... 8
5.1 SAFETY FACTOR.................................................................................................................................................8

5.2 GROUNDING.................................................................................................................................................8
5.3 INTEGRAL EARTHING ..........................................................................................................................................8
6. MAINTENANCE AND LIFE ............................................................................................................................... 8
7. TESTING......................................................................................................................................................... 8
7.1 TYPE TESTS ....................................................................................................................................................8

7.2 ROUTINE AND ACCEPTANCE TESTS ..............................................................................................................8
7.3 TESTING AT SITE................................................................................................................................................9
8. INSTALLATION ............................................................................................................................................... 9
9. DATA SHEET FOR BUS DUCTS....................................................................................................................... 10
Page 3 of 10

1. DETAILED DESCRIPTION OF THE EQUIPMENT AND ITS

APPLICATION IN DMRC –LT BUS BAR TRUNKING SYSTEM (BUS
DUCT) - COMPACT SANDWICH TYPE
This specification is intended for design, manufacture, transporting, installation and

testing at site of compact sandwich type Aluminum/Copper conductor LT Bus Bar
Trunking system (Bus duct) suitable for indoor/outdoor installations as specified in
the attached data sheet.
415 V, 3 Phase, 50 Hz, self cooled, sandwich construction Al/Cu bus duct as per
the specific requirements shall be supplied. The bus bar systems offered shall be
complete with all necessary accessories like elbows, off sets, reducers etc.
2. GOVERNING SPECIFICATION
LT Bus Bar Trunking system (Bus duct) shall conform to IEC 61439 part -6.
2.1 STANDARDS
LT Bus Bar Trunking system (Bus ducts) shall satisfy the requirements given below
and shall also comply with standards in force when the bus ducts are
manufactured, particularly which are in the following table. (Unless otherwise
stipulated in the specifications, the latest version of the following Standards shall be
applicable): -
Standard # Description
IEC 61439- 6 Low-voltage switchgear and control gear assemblies -
Part 6: Busbar trunking systems (busways)
IEC 61439- 1 Low-voltage switchgear and control gear assemblies -

Part 1: General rules
IEC 60529 Degrees of protection provided by enclosures (IP Code)
Page 4 of 10

2.2 ABBREVIATIONS
 IEC – International Electro technical Council
 IS - Indian Standard
 LV /LT – Low Voltage/Low Tension
 MCCB – Moulded Case Circuit Breaker
 GI – Galvanized Iron
3. TECHNICAL REQUIREMENTS
415 V, 3 Phase, 50 HZ, self cooled, sandwich construction, Aluminium/Copper
(as specified) bus duct as per the following specific requirements shall be
supplied -
3.1 BUS BARS
3.1.1 For Aluminum Bus duct, Bus bar shall be fabricated from aluminium and the
conductors shall be continuously nickel/ tinned / copper / suitably plated for the
entire length. For Copper Bus duct, the bus bars shall be of high conductivity
copper of 99.9% pure grade and shall be continuously nickel/ tinned / copper /
suitably plated for the entire length. Rating of busbar shall be as per data sheet,
and it shall be 3Phase +100% Neutral+ 50% integral earth including bends.
3.1.2 Busbar conductors shall be insulated with single/multilayer of insulation of class

F. Electric connection shall be made at joints by single/multi bolt joint
construction which ever suited. Joints shall be realized by a torque spanner
(wrench) and shall be set as per the manufacturer design. To prevent the joints
to be damaged during transport, they shall be protected by plastic caps, which
shall be removed before installation. Standard or designed locking system shall
be put in place to prevent loosening of any screw and requiring any tightening
schedule during maintenance. The design should have a provision to identify
unraveling of the screw/nut by a degree and a marker to indicate, if the bolt has
shifted from net position.
3.1.3 Each busbar shall be jointed to the adjacent section by single/multi bolt-joint
clamps without drilling the busbar. Joint between two sections shall be such
that a complete sub assembly is removable so that isolation of individual
sections is possible without disturbing other sections.
3.1.4 Inspection windows shall be provided over the joints to check tightness.
Page 5 of 10

3.1.5 Flexible connections shall be provided by braided or multi leafed conductors for
termination
3.2 ENCLOSURE
3.2.1 The enclosures of Bus ducts shall be totally enclosed non ventilated type.
Ingress protection for the enclosures shall be IP 54 for indoor Busduct and IP
65 for outdoor Busduct as per IEC 60529.The enclosure of Bus Trunking
System shall be fabricated from 1.6 mm thick CRCA sheet steel/ GI/ extruded Al
and shall be powder coated to color shade RAL 7032 after regress metal
treatment process.
3.2.2 Enclosure shall be rendered dust proof and vermin proof by adequate gasketing
etc. to provide ingress protection of not less than IP 54 for indoor Busd uct and
IP 65 for outdoor Bus duct as per IEC 60529. The gasket material shall be
suitable for more than the class of insulation. The Bus bar Trunking System
shall be manufactured in convenient section to facilitate easy transportation and
installation. The sections shall be connectable to form vertical or horizontal
runs as required. Each section shall be provided with suitable support
arrangement from walls / ceilings as required. Expansion joints may be
provided as per manufacturer’s design and recommendation.
3.3 FLANGED END BOX

Flanged end box shall be provided to accommodate flange end for connecting
the bus trunking with the flanges of panels, transformers and DG Sets etc.
through flexible connections. Phase matching of bus trunking with equipment
shall be done prior to installation.
3.4 EXPANSION JOINTS

The bus bar system shall be equipped with standard expansion joints or with
expansion bolts in each unit length to compensate thermal elongation of the bus
bar.As far local conditions permit, the longest bus bar unit lengths shall be used
to minimize electrical losses at the butt or bolted connections of the bus bars.The
bus bar junction points shall be suitably marked for identification.
4. ADDITIONAL REQUIREMENTS
4.1 RISING MAIN PLUG-IN TAP-OFF BOXES -FEAUTURES
4.1.1 Tap Off Provision
Page 6 of 10

Rising Mains shall have provision to install the tap off boxes at minimum
3 locations in standard length of 3 m. Plug in points shall have a hinged sheet
metal that provides IP protection similar to specified for Bus duct. There shall be
provision for up to 3 plug in tap off boxes. Rating of plug in tap off boxes shall
start from 100 ampere and shall be up to and including 400 ampere. Plug in tap
off boxes shall have an electrical interlock mechanism which also insures that
plug in tap off box cannot be removed mechanically from the bus bar when the
box is at ON position. Tap off boxes shall be suitable for any brand of MCCB.
Tap off boxes shall be manufactured of similar material and color as main bus
duct. Tap off boxes shall be plug in type with earth contact to make first and
break last. Tap off boxes shall have spring loaded contacts for uniform contact
pressure on bus bars. Tap off boxes shall be provided with door interlocking and
interlocking with bus trunking to ensure plug in and plug out possible only in OFF
condition. All tap off boxes shall be compatible with all rating of bus trunking and
shall be suitable for interchanging between sandwich/air insulated trunking. Tap
off outlets shall be available as required by the system design. Tap off outlets
shall have safety shutters to prevent access to live bus bars when not in use.
Degree of protection in the open conditions with shrouding shall be IP 2X to offer
personal safety protection.
4.1.2 THRUST PADS

Thrust Pads shall be provided in the raising main systems for necessary support
to the rising mains and to prevent bus bar expansion in down ward direction.
4.1.3 ACCESSORIES
Bus trunking system shall be complete with all accessories like bends, Ts,
vertical anchors, expansion joints, flexible connections etc. to suit site
requirements. Bus trunking systems shall be complete in all respects. All
accessories shall be deemed to be included in the straight length of the bus duct
and rising mains.
4.2 TERMINAL ARRANGEMENTS

Suitable arrangements shall be available for cable terminations so that the cable
weight doesn’t come on the terminals. The terminal on HV & LV shall be suitable
for receiving copper flexible cable as specified in 3.1.5 and termination with cable
gland and anodized hard wire for the cable termination.
Page 7 of 10

5. SAFETY
5.1 SAFETY FACTOR
The contractor will submit the Bus duct support calculation incorporating safety
factor not less than or equal to 3 and dead weight of the bus duct along with
hanging arrangement detail.
5.2 GROUNDING
Bus trunking system shall be provided with two independent earthing GI
conductors size of at least 50x6 (mm)/ as suitable throughout the length of the
system. The earth flats shall be effectively connected to the enclosure by riveting
/bolting. End covers shall be provided as required. Neutral shall have same cross
section as phases.
All parts of the bus enclosure, supporting structures and equipment frames shall
be bonded to the ground bus.
5.3 INTEGRAL EARTHING

Integral earthing comprised of Aluminum of 50% capacity should be provided
need not be provided as enclosure is available which should be part of the
housing itself.
6. MAINTENANCE AND LIFE

The LT bus duct should be designed for maintenance free best service life in the
industry and not less than 30 years for all types of installation & under prescribed
environmental conditions.
7. TESTING
7.1 TYPE TESTS
LT Bus Bar Trunking system (Bus duct) offered shall comply to verification and
Type test requirements of IEC 61439-6. Type testing shall be conducted from
accredited Lab. Copies of the test certificates for same rating shall be submitted
at the time of vendor approval. These shall not be more than 5 years old.
7.2 ROUTINE AND ACCEPTANCE TESTS
Page 8 of 10

Testing at manufacturers’ works shall be conducted before dispatch as per

Routine verification requirements as per IEC 61439-6.
7.3 TESTING AT SITE

 Physical check including checking damage/crack in any components,
tightness of bolts and connections etc.
 Insulation test after installation according to manufacturers test procedures
 Testing earth continuity.
8. INSTALLATION
 Installation of the Bus Duct shall be carried out as per manufacturer’s
instructions and installation shall be verified by the manufacturer before
energising.
 For Bus Duct horizontal runs, horizontal expansion units shall be provided at
suitableintervals at least every 40 m and at expansion joints of the building
structure and the system shall be supported at least every 1.5 m.
 Annular space around or Bus Ducts while crossing walls shall be filled up by
sealing material by contractor in accordance with the manufacturer’s
instructions.
Page 9 of 10

9. DATA SHEET FOR BUS DUCTS

Rated
S.No. 3200 A 4000 A 5000 A
Current
1 Type Compact sandwich Compact sandwich Compact sandwich
2 3 Phase, 4 wire, AC, 3 Phase, 4 wire, AC, 3 Phase, 4 wire, AC,
Supply system
415 Volts, 50 HZ 415 Volts, 50 HZ 415 Volts, 50 HZ
Bus Bar
3 Aluminium Aluminium Copper
Conductor
4 Insulation Class F Class F Class F
Rated
5 Insulation 1000 V 1000 V 1000 V
Voltage
Power
6 frequency 2.5 kV 2.5 kV 2.5 kV
withstand
Short Circuit
7 65 kA for 1 sec 65 kA for 1 sec 70 kA for 1 sec
Rating
3200 A, 3P, + 100% 4000 A, 3P, + 100% 5000 A, 3P, + 100%
8 Current Rating N, + 50% integral N, + 50% integral N, + 50% integral
earth earth earth
As per IEC As per IEC As per IEC
Temperature standards standards standards
9
Rise *
IP 65 for outdoor IP 65 for outdoor IP 65 for outdoor

Degree of
10 use, IP 54 for indoor use, IP 54 for indoor use, IP 54 for indoor
Protection
use use use
The Bus Duct Systems offered shall be complete with all necessary accessories
like elbows, offsets, reducers etc. *Design data in support of temperature rise being
within permissible limits shall be furnished along with the tender as per IEC standards.
Page 10 of 10

DMRC Electrical Standards & Design Wing (Desdw) : Delhi Metro Rail Corporation Limited

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DMRC Electrical Standards & Design Wing DMES-T/0021

SPECIFICATIONS FOR LT BUS BAR TRUNKING SYSTEM (BUS DUCT) – Draft-1

DELHI METRO RAIL CORPORATION LIMITED