5000 AMPS BUS BAR CALCULATION

PROJECT Bus duct Revision : 00

CLIENT Solon Date : 28-10-2020
CONSULTANT Srivaari electricals
Document ID SVEPL 11-2020
1 Input Data
1.1 Type : Bus duct
1.2 System : 3PH ,3 Wire
1.3 Rated Voltage : 690
1.4 Power Frequency : 50 Hz.

1.5 Panel Max. Current Rating in Amp (Design) : 5000

Fault Current & Duration (KA RMS Symmetrical for

1.6 : 80
1 Sec.)

1.7 Ambient Temperature (Deg. C.) : 50

1.8 Maximum Bus bar Temperature (Deg. C.) : 85
1.9 Maximum Enclosure Temperature (Deg. C.) : 70
1.10 Degree of Protection : IP: 55
Bus bar Size for Phase : 1 x 150 x 12 MM
Bus bar Size for Neutral : Nil
No. of Runs : 4
1.11
No. of times Interleaved : 1
Width of Bus Bar in mm : 150
Thickness of Bus Bar in mm : 12
1.12 Bus bar cross section for Neutral in Sq.mm Nil
1.13 Cross section of Bus bar Selected in Sq. mm : 7200
1.14 Type of Insulator : SMC support
1.15 Basic Insulation Level: 1.1 KV
a One Minute Power Frequency voltage : 2.5KV RMS

1.16 Painting:
a. Enclosure Interior & Exterior : Epoxy paint RAL-7032
b. Bus bar : Heat Shrinkable Sleeved.
1.17 Minimum Clearance:
a. Phase to Phase : 25 mm
b. Phase to Earth : 20 mm
1.18 : IS: 8623 Construction
Applicable Standard
: IS : 5082 Bus bar
1.19 Span Between 2 support : 0.50mtr. (500mm)
2 Bus duct Sizing Calculation for MCC
2.1 Short Time Thermal Withstand Capability of Bus bar

Page 1 of 12
 PROJECT Bus duct Revision : 00
CLIENT Solon Date : 28-10-2020
CONSULTANT Srivaari electricals
Document ID SVEPL 11-2020

Minimum Cross Sectional Area of Busbar (A) In Sq. ( Isc / √T ) / {14 x 10⁴ √log₁₀ [T1
=
Inches +258)/(T2+258)] }

Isc = Short Circuit Symmetrical Fault Current in KA = 80

T = Fault duration in Sec = 1

T1 = Initial Temperature of Busbar in Deg.C = 85
T2 = Final Temperature in Deg.C = 200
A = Cross sectional area of busbar in Sq.inches = 1.613
A in sq.mm = A x 645.16 1040.4

2.2 Required cross sectional Area 1040.4 Sq.mm for EC grade aluminium.

Actual Cross section of Bus bar Selected (As per

2.2 = 7200
Clause1.13) in Sq.mm
Conclusion:
2.3 The required cross section 1040.4 Sq.mm is less than actual cross section 7200 Sq.mm of the bus bar
selected. Hence, the bus bar size chosen is safe for the envisaged system.
3 Bus bar Selection for Continuous Current Rating :
3.10 Bus bar Selected : As per Clause1.11
Open air rating of bus bar for 50 Deg. C rise over
: 2620
ambient in Amps.
3.11
No. of times Interleaved (As per Clause1.11) : 1 x 2620
Overall Rating of Bus Bar in Amps. : 2620
3.12 Phase spacing in mm. : 150
3.13 Enclosed Size in (W x L x H ) mm : 2500 x 650 x 300 mm
3.14 Bus bar Enclosed in (W x H ) mm : 350 x 300 mm
3.15 Design Ambient Temperature : 50
3.16 Maximum allowable temp. rise : 35

3.17 Enclosure Material : MS Steel

3.18 De-rating / Up rating:

a Ambient correction factor for 45 Deg. Rise = 0.95

Page 2 of 12
 PROJECT Bus duct Revision : 00
CLIENT Solon Date : 28-10-2020
CONSULTANT Srivaari electricals
Document ID SVEPL 11-2020

b Enclosure correction factor corresponding to bus bar = 0.9

c Enclosure Correction factor Material (MS) = 1

d Proximity Effect Factor = 0.85
e Bus bar Configuration Factor = 0.9
g Combined Correction Factor = 0.65
De-rated Current rating of bus bar after applying
3.19 = 2620 x 0.65
Correction factor in Amps.
= 6854.7
3.20 Rating of Panel required (As per Clause 1.5) = 5000
Conclusion :
3.21 The de-rated Current rating 6854.7 amp of Panel selected is more than the required current rating 5000 amp
of Bus duct Bus bar. Hence, the bus bar size chosen is safe for the envisaged system.
4 Support Insulator Span Calculation During Short Circuit
Fm = Peak Electromagnetic force along the centre
4.10 = K x 16 x Isc² x 10⁻⁴ / S
line of busbar without enclosure

a Isc = Short Circuit Symmetrical Fault Current in KA = 80

b S = Phase spacing in Meter = 0.120

c K = Multiplying factor (s-a)/(a+b) = 0.904
corresponding to a that is 60 = 0.4 (Refering to curve K is 0.9)
Fm (Nm / cm² ) = 36864.0
Fm ( Kg / cm² ) = (Fm x 0.1019716) = 3759.081
4.12 F = Force acting on top of the insulator = Fm (H+h)/4H
a Where, H = Cantilever Height of insulator in mm = 42

h = Distance between surface of insulator to centre

b = 85
of Bus bar in mm
F = 2841.7
Cantilever Strength of insulator / safety factor x
4.13 Average span to be addopted in mm =
F
= Sk / (SF x F )
a SK = Cantilever strength of insulator(Kg/cm²) = 2000
b SF = Safety factor = 1.5
Length of Span of insulator in mm = 469.205
Adopted Span is OK
Conclusion:
4.4
Average span of 469 mm is required but span adopted is 500 mm, hence it is safe for the system envisaged.

5 Temperature Rise Calculation

Where, I1=Calculated Rating in Amps (After
5.1 = 6854.7
deration) As per Clause 3.19

Page 3 of 12
 PROJECT Bus duct Revision : 00
CLIENT Solon Date : 28-10-2020
CONSULTANT Srivaari electricals
Document ID SVEPL 11-2020

5.2 I2 = Specified Rating in Amps as per clause 1.5 = 5000

5.3 T1 = Max. Temp. Rise (in Deg.C) Specified = 35

5.4 T2 = Temp. Rise in Deg. C to be calculated as = ( I1 / I2 ) = ( T1 / T2)0.61
T2 = T1 / (I1 / I2 )1.64
= 20.86
Calculated Temperature is = OK
Conclusion :
5.5 The Calculated Temperature rise of bus bar is 20.86 Deg. C, which is within the design Specified Temp. 35
Deg. C and it is safe for the System envisaged.

Prepared By: Ganesh Approved By : Anand

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 4000 A BUSBAR SIZING CALCULATION

PROJECT CPRI PLANT Revision : 01

CLIENT M/s. K.P.R. SUGAR MILL LTD Date : 24-05-2012
CONSULTANT M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. No. of Sheet - 4
EPC ISGEC HEAVY ENGINEERING LIMITED
CONTRACTOR
Document ID KR11-10302-CLC-001
1 Input Data
1.1 Type of Panel : Cubical Type
1.2 System : 3PH ,3 Wire / 4 Wire
1.3 Rated Voltage : 415V
1.4 degree of Protection : 50 Hz.

1.5 Panel Max. Current Rating in Amp (Design) : 4000

Fault Current & Duration (KA RMS Symmetrical for

1.6 : 65
1 Sec.)

1.7 Ambient Temperature (Deg. C.) : 50

1.8 Maximum Bus bar Temperature (Deg. C.) : 85
1.9 Maximum Enclosure Temperature (Deg. C.) : 70
1.10 Degree of Protection : IP: 52 & IP: 42 for ACB Incomer
Bus bar Size for Phase : 4 x 1 x 125 x 10 MM
Bus bar Size for Neutral : 2 x 125 x 10 MM
No. of Runs : 4
1.11
No. of times Interleaved : 1
Width of Bus Bar in mm : 125
Thickness of Bus Bar in mm : 10
1.12 Bus bar cross section for Neutral in Sq.mm 600
1.13 Cross section of Bus bar Selected in Sq. mm : 5000
1.14 Type of Insulator : SMC support
1.15 Basic Insulation Level:
a One Minute Power Frequency voltage : 2.5KV RMS

1.16 Painting:
a. Enclosure Interior & Exterior : Epoxy paint RAL-7032, Siemens Grey
b. Bus bar : Heat Shrinkable Sleeved.
1.17 Minimum Clearance:
a. Phase to Phase : 25 mm
b. Phase to Earth : 20 mm
: IS: 8623 Construction
1.18 Applicable Standard
: IS : 5082 Bus bar
1.19 Degree of Protection : IP: 54 for Indoor & IP: 55 for Outdoor
1.20 Span Between 2 support : 0.5mtr. (500mm)

Page 5 of 12
 4000 A BUSBAR SIZING CALCULATION

PROJECT CPRI PLANT Revision : 01

CLIENT M/s. K.P.R. SUGAR MILL LTD Date : 24-05-2012
CONSULTANT M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. No. of Sheet - 4
EPC ISGEC HEAVY ENGINEERING LIMITED
CONTRACTOR
Document ID KR11-10302-CLC-001
2 Bus duct Sizing Calculation for MCC
2.1 Short Time Thermal Withstand Capability of Bus bar
Minimum Cross Sectional Area of Busbar (A) In Sq. ( Isc / √T ) / {14 x 10⁴ √log₁₀ [T1
=
Inches +258)/(T2+258)] }

Isc = Short Circuit Symmetrical Fault Current in KA = 50

T = Fault duration in Sec = 3

T1 = Initial Temperature of Busbar in Deg.C = 85
T2 = Final Temperature in Deg.C = 200
A = Cross sectional area of busbar in Sq.inches = 0.581883504612064
A in sq.mm = A x 645.16 375.408

2.2 Required cross sectional Area 650.226 Sq.mm for pure aluminium.

Actual Cross section of Bus bar Selected (As per

2.2 = 5000
Clause1.13) in Sq.mm
Conclusion:
2.3 The required cross section 650.226 Sq.mm is less than actual cross section 1000 Sq.mm of the bus bar
selected. Hence, the bus bar size chosen is safe for the envisaged system.
3 Bus bar Selection for Continuous Current Rating :
3.10 Bus bar Selected : As per Clause1.11
Open air rating of bus bar for 50 Deg. C rise over
: 1500
ambient in Amps.
3.11
No. of times Interleaved (As per Clause1.11) : 1 x 1500
Overall Rating of Bus Bar in Amps. : 1500
3.12 Phase spacing in mm. : 150
3.13 Enclosed Size in (W x D x H ) mm : 4400 x 800 x 2400 mm
3.14 Bus bar Enclosed in (W x D ) mm : 800 x 400 mm
3.15 Design Ambient Temperature : 50 Deg. C
3.16 Maximum allowable temp. rise : 35 Deg. C

3.17 Enclosure Material : MS Steel

Page 6 of 12
 4000 A BUSBAR SIZING CALCULATION

PROJECT CPRI PLANT Revision : 01

CLIENT M/s. K.P.R. SUGAR MILL LTD Date : 24-05-2012
CONSULTANT M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. No. of Sheet - 4
EPC ISGEC HEAVY ENGINEERING LIMITED
CONTRACTOR
Document ID KR11-10302-CLC-001
3.18 De-rating / Up rating:
a Ambient correction factor for 35 Deg. Rise = 0.9

b Enclosure correction factor corresponding to bus bar = 0.87

c Enclosure Correction factor Material (MS) = 0.9

d Proximity Effect Factor = 0.95
e Bus bar Configuration Factor = 1
g Combined Correction Factor = 0.67
De-rated Current rating of bus bar after applying
3.19 = 1500 x 0.67
Correction factor in Amps.
= 1004.1975
3.20 Rating of Panel required (As per Clause 1.5) = 4000
Conclusion :
3.21 The de-rated Current rating 1004.19 amp of Panel selected is more than the required current rating 800 amp
of Bus duct Bus bar. Hence, the bus bar size chosen is safe for the envisaged system.
4 Support Insulator Span Calculation During Short Circuit
Fm = Peak Electromagnetic force along the centre
4.10 = K x 16 x Isc² x 10⁻⁴ / S
line of busbar without enclosure

a Isc = Short Circuit Symmetrical Fault Current in KA = 65

b S = Phase spacing in Meter = 0.250

c K = Multiplying factor (s-a)/(a+b) = 0.904
corresponding to a that is 60 = 0.4 (Reffering to curve K is 0.9)
Fm (Nm / cm² ) = 24336.000
Fm ( Kg / cm² ) = (Fm x 0.1019716) = 2481.581
4.12 F = Force acting on top of the insulator = Fm (H+h)/4H
a Where, H = Cantilever Height of insulator in mm = 38

h = Distance between surface of insulator to centre

b = 75
of Bus bar in mm
F = 1844.85945334737
Cantilever Strength of insulator / safety factor x
4.13 Average span to be addopted in mm =
F
= Sk / (SF x F )
a SK = Cantilever strength of insulator(Kg/cm²) = 1600
b SF = Safety factor = 2.5
Length of Span of insulator in mm = 346.910
Adopted Span is CHECK
Conclusion:
4.4 Average span of 586.278 mm is required but span adopted is 500 mm, hence it is safe for the system
envisaged.

Page 7 of 12
 4000 A BUSBAR SIZING CALCULATION

PROJECT CPRI PLANT Revision : 01

CLIENT M/s. K.P.R. SUGAR MILL LTD Date : 24-05-2012
CONSULTANT M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. No. of Sheet - 4
EPC ISGEC HEAVY ENGINEERING LIMITED
CONTRACTOR
Document ID KR11-10302-CLC-001
5 Temperature Rise Calculation
Where, I1=Calculated Rating in Amps (After
5.1 = 1004.1975
deration) As per Clause 3.19

5.2 I2 = Specified Rating in Amps as per clause 1.5 = 4000

5.3 T1 = Max. Temp. Rise (in Deg.C) Specified = 35

5.4 T2 = Temp. Rise in Deg. C to be calculated as = ( I1 / I2 ) = ( T1 / T2)0.61
T2 = T1 / (I1 / I2 )1.64
= 337.65
Calculated Temperature is = CHECK
Conclusion :
5.5 The Calculated Temperature rise of bus bar is 24.11 Deg. C, which is within the design Specified Temp. 35
Deg. C and it is safe for the System envisaged.

Prepared By: Ganpat C Checked By : Kamlakar D. Approved By : A.B.H

Page 8 of 12
 1000 A MCC BUSBAR SIZING CALCULATION

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT Revision : 01

CLIENT M/s. K.P.R. SUGAR MILL LTD Date : 24-05-2012
CONSULTANT M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. No. of Sheet - 4
EPC ISGEC HEAVY ENGINEERING LIMITED
CONTRACTOR
Document ID KR11-10302-CLC-001
1 Input Data
1.1 Type of Panel : Cubical Type
1.2 System : 3PH ,3 Wire / 4 Wire
1.3 Rated Voltage : 415V
1.4 degree of Protection : 50 Hz.

1.5 Panel Max. Current Rating in Amp (Design) : 1000

Fault Current & Duration (KA RMS Symmetrical for

1.6 : 50
1 Sec.)

1.7 Ambient Temperature (Deg. C.) : 50

1.8 Maximum Bus bar Temperature (Deg. C.) : 85
1.9 Maximum Enclosure Temperature (Deg. C.) : 70
1.10 Degree of Protection : IP: 52 & IP: 42 for ACB Incomer
Bus bar Size for Phase : 1 x 1 x 125 x 10 MM
Bus bar Size for Neutral : 1 x 125 x 06 MM
No. of Runs : 1
1.11
No. of times Interleaved : 1
Width of Bus Bar in mm : 125
Thickness of Bus Bar in mm : 10
1.12 Bus bar cross section for Neutral in Sq.mm 750
1.13 Cross section of Bus bar Selected in Sq. mm : 1250
1.14 Type of Insulator : SMC support with ribbed construction
1.15 Basic Insulation Level:
a One Minute Power Frequency voltage : 2.5KV RMS

1.16 Painting:
a. Enclosure Interior & Exterior : Epoxy paint RAL-7032, Siemens Grey
b. Bus bar : Heat Shrinkable Sleeved.
1.17 Minimum Clearance:
a. Phase to Phase : 25 mm
b. Phase to Earth : 20 mm
: IS: 8623 Construction
1.18 Applicable Standard
: IS : 5082 Bus bar
1.19 Degree of Protection : IP: 54 for Indoor & IP: 55 for Outdoor
1.20 Span Between 2 support : 0.5mtr. (500mm)

Page 9 of 12
 1000 A MCC BUSBAR SIZING CALCULATION

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT Revision : 01

CLIENT M/s. K.P.R. SUGAR MILL LTD Date : 24-05-2012
CONSULTANT M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. No. of Sheet - 4
EPC ISGEC HEAVY ENGINEERING LIMITED
CONTRACTOR
Document ID KR11-10302-CLC-001
2 Bus duct Sizing Calculation for MCC
2.1 Short Time Thermal Withstand Capability of Bus bar
Minimum Cross Sectional Area of Busbar (A) In Sq. ( Isc / √T ) / {14 x 10⁴ √log₁₀ [T1
=
Inches +258)/(T2+258)] }

Isc = Short Circuit Symmetrical Fault Current in KA = 50

T = Fault duration in Sec = 1

T1 = Initial Temperature of Busbar in Deg.C = 85
T2 = Final Temperature in Deg.C = 200
A = Cross sectional area of busbar in Sq.inches = 1.00785179407433
A in sq.mm = A x 645.16 650.226

2.2 Required cross sectional Area 650.226 Sq.mm for pure aluminium.

Actual Cross section of Bus bar Selected (As per

2.2 = 1250
Clause1.13) in Sq.mm
Conclusion:
2.3 The required cross section 650.226 Sq.mm is less than actual cross section 1250 Sq.mm of the bus bar
selected. Hence, the bus bar size chosen is safe for the envisaged system.
3 Bus bar Selection for Continuous Current Rating :
3.10 Bus bar Selected : As per Clause1.11
Open air rating of bus bar for 50 Deg. C rise over
: 1850
ambient in Amps.
3.11
No. of times Interleaved (As per Clause1.11) : 1 x 1850
Overall Rating of Bus Bar in Amps. : 1850
3.12 Phase spacing in mm. : 150
3.13 Enclosed Size in (W x D x H ) mm : 5500 x 800 x 2400 mm
3.14 Bus bar Enclosed in (W x D ) mm : 800 x 400 mm
3.15 Design Ambient Temperature : 50 Deg. C
3.16 Maximum allowable temp. rise : 35 Deg. C

3.17 Enclosure Material : MS Steel

Page 10 of 12
 1000 A MCC BUSBAR SIZING CALCULATION

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT Revision : 01

CLIENT M/s. K.P.R. SUGAR MILL LTD Date : 24-05-2012
CONSULTANT M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. No. of Sheet - 4
EPC ISGEC HEAVY ENGINEERING LIMITED
CONTRACTOR
Document ID KR11-10302-CLC-001
3.18 De-rating / Up rating:
a Ambient correction factor for 35 Deg. Rise = 0.9

b Enclosure correction factor corresponding to bus bar = 0.87

c Enclosure Correction factor Material (MS) = 0.9

d Proximity Effect Factor = 0.95
e Bus bar Configuration Factor = 1
g Combined Correction Factor = 0.67
De-rated Current rating of bus bar after applying
3.19 = 1850 x 0.67
Correction factor in Amps.
= 1238.51025
3.20 Rating of Panel required (As per Clause 1.5) = 1000
Conclusion :
3.21 The de-rated Current rating 1238.51 amp of Panel selected is more than the required current rating 1000 amp
of Bus duct Bus bar. Hence, the bus bar size chosen is safe for the envisaged system.
4 Support Insulator Span Calculation During Short Circuit
Fm = Peak Electromagnetic force along the centre
4.10 = K x 16 x Isc² x 10⁻⁴ / S
line of busbar without enclosure

a Isc = Short Circuit Symmetrical Fault Current in KA = 50

b S = Phase spacing in Meter = 0.250

c K = Multiplying factor (s-a)/(a+b) = 0.904
corresponding to a that is 60 = 0.4 (Reffering to curve K is 0.9)
Fm (Nm / cm² ) = 14400.000
Fm ( Kg / cm² ) = (Fm x 0.1019716) = 1468.391
4.12 F = Force acting on top of the insulator = Fm (H+h)/4H
a Where, H = Cantilever Height of insulator in mm = 38

h = Distance between surface of insulator to centre

b = 75
of Bus bar in mm
F = 1091.63281263158
Cantilever Strength of insulator / safety factor x
4.13 Average span to be addopted in mm =
F
= Sk / (SF x F )
a SK = Cantilever strength of insulator(Kg/cm²) = 1600
b SF = Safety factor = 2.5
Length of Span of insulator in mm = 586.278
Adopted Span is OK
Conclusion:
4.4 Average span of 586.278 mm is required but span adopted is 500 mm, hence it is safe for the system
envisaged.

Page 11 of 12
 1000 A MCC BUSBAR SIZING CALCULATION

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT Revision : 01

CLIENT M/s. K.P.R. SUGAR MILL LTD Date : 24-05-2012
CONSULTANT M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD. No. of Sheet - 4
EPC ISGEC HEAVY ENGINEERING LIMITED
CONTRACTOR
Document ID KR11-10302-CLC-001
5 Temperature Rise Calculation
Where, I1=Calculated Rating in Amps (After
5.1 = 1238.51025
deration) As per Clause 3.19

5.2 I2 = Specified Rating in Amps as per clause 1.5 = 1000

5.3 T1 = Max. Temp. Rise (in Deg.C) Specified = 35

5.4 T2 = Temp. Rise in Deg. C to be calculated as = ( I1 / I2 ) = ( T1 / T2)0.61
T2 = T1 / (I1 / I2 )1.64
= 24.64
Calculated Temperature is = OK
Conclusion :
5.5 The Calculated Temperature rise of bus bar is 24.64 Deg. C, which is within the design Specified Temp. 35
Deg. C and it is safe for the System envisaged.

Prepared By: Ganpat C Checked By : Kamlakar D. Approved By : A.B.H

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