Panel Design & Calculate Size of Bus bar

AUGUST 5, 2014 33 COMMENTS

Example: Calculate Size of Bus bar having Following Details

Bus bar Current Details:

Rated Voltage = 415V,50Hz ,

Desire Maximum Current Rating of Bus bar =630Amp.

Fault Current (Isc)= 50KA ,Fault Duration (t) =1sec.

Bus bar Temperature details:

Operating Temperature of Bus bar ()=85C.

Final Temperature of Bus bar during Fault(1)=185C.

Temperature rise of Bus Bar Bar during Fault (t=1-)=100C.

Ambient Temperature (n) =50C.

Maximum Bus Bar Temperature Rise=55C.

Enclosure Details:

Installation of Panel= Indoors (well Ventilated)

Altitude of Panel Installation on Site= 2000 Meter

Panel Length= 1200 mm ,Panel width= 600 mm, Panel Height= 2400 mm

Bus bar Details:

Bus bar Material= Copper

Bus bar Strip Arrangements= Vertical

Current Density of Bus Bar Material=1.6

Temperature Co efficient of Material Resistance at 20c(20)= 0.00403

Material Constant(K)= 1.166

Bus bar Material Permissible Strength=1200 kg/cm2

Bus bar Insulating Material= Bare

Bus bar Position= Edge-mounted bars

Bus bar Installation Media= Non-ventilated ducting

Bus bar Artificial Ventilation Scheme= without artificial ventilation

Bus bar Size Details:

Bus bar Width(e)= 75 mm

Bus bar Thickness(s)= 10 mm

Number of Bus Bar per Phase(n)= 2 No

Bus bar Length per Phase(a)= 500 mm

Distance between Two Bus Strip per Phase(e)= 75 mm

Bus bar Phase Spacing (p)= 400 mm

Total No of Circuit= 3 No.

Bus bar Support Insulator Detail:

Distance between insulators on Same Phase(l)= 500 mm

Insulator Height (H)= 100 mm

Distance from the head of the insulator to the bus bar center of gravity (h)= 5 mm

Permissible Strength of Insulator (F)=1000 Kg/cm2

Calculation:
(1) De rating Factors for Bus bar:

(1) Per Phase Bus Strip De rating Factor (K1):

Bus bar Width(e) is 75mm and Bus bar Length per Phase(a) is 500mm so e/a is 75/500=0.15

No of Bus bar per phase is 2 Nos.

From following table value of de rating factor is 1.83

Number of Bus Bar Strip per Phase (K1)
No of Bus Bar per Phase
e/a
1

0.05

1.63

2.4

0.06

1.73

2.45

0.08

1.76

2.5

0.1

1.8

2.55

0.12

1.83

2.6

0.14

1.85

2.63

0.16

1.87

2.65

0.18

1.89

2.68

1.91

2.7

0.2

(2) Bus bar Insulating Material De rating Factor (K2)

Bus bar having No insulating material. It is Bare so following Table

De rating Factor is 1.
Bus Bar Insulating Material (K2):

De rating Factor

Bare

PVC Sleeving

1.2

Painted

1.5

(3) Bus bar Position De rating Factor (K3)

Bus bar Position is Edge-mounted bars so following Table

De rating Factor is 1
Bus Bar Position(K3):

De rating Factor

Edge-mounted bars

1 bar base-mounted

0.95

several base-mounted bars

0.75

(4) Bus bar Installation Media De rating Factor (K4)

Bus bar Installation Media is Non-ventilated ducting so following Table

De rating Factor is 0.8

Bus Bar Installation Media(K4):

De rating Factor

Calm indoor atmosphere

Calm outdoor atmosphere

1.2

Non-ventilated ducting

0.8

(5) Bus bar Artificial Ventilation De rating Factor (K5)

Bus bar Installation Media is Non-ventilated ducting so following Table

De rating Factor is 0.9

Bus Bar Artificial Ventilation Scheme (K5):

De rating Factor

without artificial ventilation

0.9

with artificial ventilation

(6) Enclosure & Ventilation De rating Factor (K6)

Bus bar Area per Phase = Bus width X Bus Thickness X Length of Bus X No of Bus bar per Phase

Bus bar Area per Phase = 75x10xX500X2= 750000mm

Total Bus bar Area for Enclosure= No of Circuit X( No of Phase + Neutral )X Bus bar Area per Phase

Here we used Size of Neutral Bus is equal to Size of Phase Bus

Total Bus bar Area for Enclosure=3X(3+1)X750000mm

Total Bus bar Area for Enclosure=9000000 Sq.mm

Total Enclosure Area= width X Height X Length

Total Enclosure Area=1200x600x2400=1728000000 Sq.mm

Total Bus bar Area for Enclosure / Total Enclosure Area =9000000/1728000000

Total Bus bar Area for Enclosure / Total Enclosure Area=0.53%

Bus bar Artificial Ventilation Scheme is without artificial ventilation so following Table

De rating Factor is 0.95

Volume of Enclosure & Ventilation De rating Factor (K6)

cross Section area of Bus

Indoors ( Panel is

Indoors ( Panel is Poorly

bar/Total Bus Bar Area

well Ventilated)

Ventilated)

0%

0.95

0.85

0.65

1%

0.95

0.85

0.65

5%

0.9

0.7

0.6

10%

0.85

0.65

0.5

(7) Proxy Effect De rating Factor (K7)

Bus bar Phase Spacing (p) is 400mm.

Bus bar Width (e) is 75mm and Space between each bus of Phase is 75mm so

Total Bus length of Phase with spacing (w) =75+75+75+75+75=225mm

Bus bar Phase Spacing (p) / Total Bus length of Phase with spacing (w) = 400 / 225 =2

From following Table De rating factor is 0.82

Proxy Effect (K7):

De rating Factor

0.82

0.82

0.82

0.89

0.95

0.99

Outdoor

(8) Altitude of Bus Bar installation De rating Factor (K8)

Altitude of Panel Installation on Site is 2000 meter so following Table

De rating Factor is 0.88

Altitude of installation site (Meter) (K8)

De rating Factor

2200

0.88

2400

0.87

2500

0.86

2700

0.85

2900

0.84

3000

0.83

3300

0.82

3500

0.81

4000

0.78

4500

0.76

5000

0.74

Total De rating Factor= K1XK2XK3Xk4Xk5Xk6Xk7Xk8

Total De rating Factor =1.83x1x1x0.80.90.950.820.88

Total De rating Factor =0.90

(2) Bus bar Size Calculation:

Desire Current Rating of Bus bar (I2) =630 Amp

Current Rating of Bus bar after De rating Factor (I1)= I2 X De rating Factor or I2 / De rating Factor

Current Rating of Bus bar after De rating Factor (I1)=6300.9

Current Rating of Bus bar after De rating Factor (I1)=697Amp

Bus bar Cross Section Area as per Current= Current Rating of Bus bar / Current Density of Material

Bus bar Cross Section Area as per Current= 697 / 1.6

Bus bar Cross Section Area as per Current= 436 Sq.mm

Bus bar Cross Section Area as per Short Circuit= Isc X ((K/( tx100)x(1+ 20x) xt

Bus bar Cross Section Area as per Short Circuit= 50000X ((1.166/( 100100)x(1+ 0.0040385) x1

Bus bar Cross Section Area as per Short Circuit=626 Sq.mm

Select Higher Size for Bus bar Cross section area between 436 Sq.mm and 626 Sq.mm

Final Calculated Bus Bar Cross Section Area =626 Sq.mm

Actual Selected Bus bar size is 7510=750 Sq.mm

We have select 2 Nos of Bus bar per Phase hence.

Actual Bus bar cross section Area per Phase =7502= 1500 Sq.mm

Actual Cross Section Area of Bus bar =1500 Sq.mm

Actual Bus bar Size is Less than calculated Bus bar size.

(3) Forces generated on Bus Bar due to Short Circuit Current

Peak electro-magnetic forces between phase conductors (F1) = 2X(l/d)X(2.5xIsc)2/100000000

Total width of Bus bar per Phase(w)=75+75+75=225mm =2.25cm

Bus bar Phase to Phase Distance (d)=400+225=625mm=6.25cm

Peak electro-magnetic forces between phase conductors (F1) =2x(50/63)x(2.550000)2/100000000

Peak electro-magnetic forces between phase conductors (F1)=250 Kg /cm2

Peak electro-magnetic forces between phase conductors (F1)=2.5 Kg /mm2

Actual Forces at the head of the Supports or Bus Bar (F)=F1X(H+h/H)

Actual Forces at the head of the Supports or Bus Bar (F)=2.5x(100+5/100)

Actual Forces at the head of the Supports or Bus Bar (F)= 3 Kg /mm2

Permissible Strength of Insulator (F) is 10 Kg/mm2

Actual Forces at the head of the Supports or Bus Bar is less than Permissible Strength

Forces on Insulation is in within Limits

(4) Mechanical strength of the bus bars

Mechanical strength of the bus bars=(F1X i /12)x(1/ Modulus of inertia of a bus bar )

Value of Modulus of inertia of a bus bar or of a set of bus bars (i/v)

No of Bus Strip per Phase

Vertical Bus Bar (cm3)

Horizontal Bus Bar (cm3)

1.66

16.66

14.45

33.33

33

50

From above table Value of Modulus of inertia of a bus bar=14.45

Mechanical strength of the bus bars=(25050/12)X(1/14.45)

Mechanical strength of the bus bars= 72 Kg/cm2

Mechanical strength of the bus bars= 0.72 Kg/mm2

Permissible Bus bar Strength is 12 Kg/mm2

Actual Mechanical Strength is less than Permissible Strength

Mechanical strength of Bus bar is in within Limit

(5) Temperature Rise Calculation

Specified Maximum Temperature Rise (T1) is 35c

Calculated Maximum Temperature Rise (T2)=T/(log(I1/I2)1.64)

Calculated Maximum Temperature Rise (T2)=35/(Log(697/630)1.64)

Calculated Maximum Temperature Rise (T2)= 30c

Calculated Bus bar Temperature rise is less than Specified Max Temperature rise

Temperature Rise is in within Limit

Results:

Size of Bus bar = 2Nos 75x10mm per Phase.

Total No of Feeder =3 Nos

Total Nos of Bus bar = 6 Nos 75x10mm for Phase and 1Nos 75x10mm for Neutral.

Forces at the head of the Supports or Bus Bar (F)= 3kg/mm2

Mechanical strength of the bus bars= 0.7 Kg/mm2

Maximum Temperature Rise=30c