Project Report Busduct Design Cost Estimation PDF

Evaluation, Estimation & Costing of Bus ducts
Project report/Technical paper
2009
Evaluation, Design
Estimation & Costing
of Bus ducts
Prepared by
Pankaj Kumar Rajput
Pankaj Kumar
Page 1 of 27
Table of Contents
Table of Contents ................................................................................................................................................ 1
1.
Title of the Project ....................................................................................................................................... 3
2.
Objectives of the study ................................................................................................................................ 3
3.
Methodology used for carrying out the study ............................................................................................ 3
4.
Statement of the Problem ........................................................................................................................... 3
5.
Input data/Structure/Questionnaire ........................................................................................................... 3
6.
Analysis/Solution/Description ..................................................................................................................... 4
A.
Type of busbars: ...................................................................................................................................... 4
B.
Busduct design & costing: ....................................................................................................................... 7

a)
Introduction to busduct design ........................................................................................................... 7
b)
Basic constructional details of air insulated nonsegregated phase enclosed Busducts .................... 7
c)
Basic design parameters: ..................................................................................................................... 8
d)
Components of a busduct: .................................................................................................................. 8
e)
Design calculation of busduct:............................................................................................................. 9

i.
Aluminium bus bars ......................................................................................................................... 9
ii.
MS sheet for enclosure.................................................................................................................. 13
iii.
FRP sheet for support insulators ................................................................................................... 16
f)
Other design validations: ................................................................................................................... 16
g)
Calculation of weights of raw materials: ........................................................................................... 17

i.
Aluminium bus bars ....................................................................................................................... 17
ii.
MS sheet for enclosure.................................................................................................................. 17
iii.
FRP sheet for support insulators ................................................................................................... 18
h)
Calculation of cost of busduct: .......................................................................................................... 18
i)
Cost model MS Excel: ..................................................................................................................... 20
7.
Final Results ............................................................................................................................................... 22
8.
Conclusion ................................................................................................................................................. 22
9.
Scope of Future Study ............................................................................................................................... 22
Appendix 1: Derating factors for busbar ........................................................................................................... 23

Appendix 2: Standard Aluminium busbar sizes and their Ampacity table ........................................................ 24
Appendix 3: Indoor busbars Minimum clearances ......................................................................................... 25
Appendix 4: Modulus of Inertia between busbars ............................................................................................ 26
References: ........................................................................................................................................................ 27
Pankaj Kumar
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Project Report
1. Title of the Project
Evaluation, design, estimation & costing of Bus ducts
2. Objectives of the study
x
x
x
Study of types & design parameters of Busbars

Study of cost components of Busducts
Preparation of a cost module for Busducts for estimation of approximate cost
3. Methodology used for carrying out the study

x
x
x
x
x
x
x
x
Study of various types of busbars from technical books & internet

Selection of the type of Busduct for which design & cost approximation tool is to be developed
Collection of preliminary & basic design data of standard Busduct from books & internet sites.
Preparation of components breakdown structure of selected Busduct
Perform design & cost calculation of selected busduct
Development of cost module in MS Excel software
Testing of the module by taking output for a selected rating of Busduct
Validation of cost output by taking a feedback from any one manufacturer of bus duct
4. Statement of the Problem

x
x
To minimize the errors in cost approximation by the project estimation engineers in estimating
the cost of the equipment i.e. bus duct in our case, during planning phase of the project.
To improve the process of price negotiation by working out a target cost based on the cost of
components used in manufacturing of Busducts. Conventional way of negotiation is collecting
offers from the suppliers and negotiating on the basis of cost provided by the suppliers.
5. Input data/Structure/Questionnaire
x
x
x
x
x
x
x
Pankaj Kumar
Find out the details of various types of Busbars & Busducts

Prepare structured design evaluation of Busducts
Study & list down the components of Busducts
Get information & basic formula for weight & cost calculation of raw materials
Prepare structured bill of material & cost of various components of Busducts
Make a program in MS Excel to calculate the cost of Busduct by entering basic inputs
Test the program and finalize
Page 3 of 27
6. Analysis/Solution/Description
Conductors are required for distribution of power from Generators to switchgear and loads. The main
current carrying parts in an electrical system include:
x
x
x
x
Busbars
Connectors & clamps
Power cables
Live parts of the equipments
These parts carry normal load current continuously and are also subjected to high currents during faults.
The conductors are either provided with insulation or installed on insulators with adequate clearance &
creep age distances.
An aluminum or copper conductor supported by insulators that interconnects the loads and the
sources of electric power in an electric power system is known as Busbar. For higher current ratings,
generally more than 800A, the higher temperature rise & losses in cables makes the design & execution
difficult as it requires oversizing of cables. The busducts (enclosed busbars) provide an economical &
technically superior solution.
A. Type of busbars:
1) Based on installation
a) Outdoor i.e. Open or enclosed busbars subjected to installation in open sky or outside of sub
stations in open atmosphere
b) Indoor i.e. Open or enclosed busbars subjected to installation inside the substation of closed
atmosphere i.e. protected from rain, dust, vermin etc.
2) Based on type of conductors construction
a) Flexible i.e. ACSR (Aluminium Conductor Steel Reinforced) or AAC (All Aluminium Conductor)
conductors installed on insulators. These are generally used for outdoor installations. Flexible
copper links are also used to connect enclosed rigid busbars for inside or outside installations.
b) Rigid. These are in form of flats, channels or tubular pipes of Aluminium or Copper
3) Based on cooling media
a) Air insulated i.e. Open or metal enclosed busbars
b) Gas insulated i.e. Busbars enclosed in gas filled metal enclosure e.g. SF6 gas
c) Oil immersed i.e. Busbars enclosed in oil filled metal enclosure
4) Based on protective covering method
a) Open busbars i.e. Busbars which doesnt have any protective cover
b) Enclosed busbars i.e. Busbars of rigid Aluminium or copper conductors, supported on
insulators, enclosed by sheet steel or aluminium sheets ducts.
The enclosed busbars are called Busducts. Bus duct is an assembly of bus conductors with
associated connections, joints and insulating supports confined within a metal enclosure with or
without interphase barriers.
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5) Based on insulation between the phases, Busducts are of following types:

a) Nonsegregated phase Busducts. The conductors of three phases are in a common metal
enclosure without any barrier between them. Busducts used for low voltage applications are
usually nonsegregated phase busducts.
Pictorial cross sectional view of nonsegregated busduct

b) Segregated phase Busducts. The conductors of three phases are in a common metal enclosure
with metal/insulated barriers (FRP) between them. This segregation minimizes the possibility
of a short circuit between the phases. Busducts used for medium voltages i.e. above 1.1 kV,
are usually nonsegregated phase busducts.
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Pictorial view of segregated phase busduct

c) Isolated phase Busducts. For very large currents in generating stations or substations, where it
is difficult to provide circuit protection, an Isolated Phase Busduct is used. Each phase of the
circuit is run in a separate grounded metal enclosure, hence the phase are Isolated. The only
fault possible is a phasetoground fault, since the enclosures are separated. This type of bus
can be rated up to 50,000 amperes and up to hundreds of kilovolts.
Low range Typical 1 insulator

High range Typical 3 or 4 insulators
Pictorial view of isolated phase busduct
Pankaj Kumar
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B. Busduct design & costing:

Our focus of cost estimation study is Busduct i.e. enclosed bus bars.
We choose air insulated nonsegregated phase Busduct for our case study.
a) Introduction to busduct design
The dimensions of busbars are determined considering normal operating conditions i.e. rated
current. The system voltage determines the phase to phase & phase to earth distance and also
determines the height and shape of the supports to ensure adequate creepage clearance (the
shortest distance between earthed end to the conductor, along the contour along external
surface of insulator).
Design validations are done to ensure that the busbar & supports are adequate to withstand the
mechanical & thermal effects due to short circuit currents. Design validations are also done to
ensure the temperature rise of conductors & enclosure is within safe limits.
We also have to check that the period of vibration to the busbars themselves is not resonant
with the system current frequency. During normal power frequency current flow, the conducting
parts and associated insulating & other mechanical parts experience mechanical oscillations. The
nature of such oscillations depends on operating frequency & the characteristics frequency of
the equipment. In case of resonance, the structural parts are likely to fail.
b) Basic constructional details of air insulated nonsegregated phase enclosed Busducts
NSPB consists of enclosure in rectangular form with conductors in the form of flats/channels of
Aluminium/Copper material. These conductors are usually supported on FRP supports. Following
are the basic constructional details of an air insulated nonsegregated phase busduct:
i.
Bus conductor
The bus conductors shall be of Aluminium or 99%+ conductivity copper with silverplated
joints. The bars shall be mounted on track resistant material and shall be insulated their
entire length with an epoxy coating or heat shrinkable PVC sleeves for 2400V service and
above. The insulation may also be provided for service voltage below 2400V, but its not
mandatory. Typical joints of conductor buses shall be insulated with removable boots and
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Page 7 of 27
jointed by double splice plates. A typical joint may use tape or heat shrink tubing to insulate
when insulation is required.
A 50x6 mm or other suitable size of Aluminium or bare copper conductor ground bus shall
be installed and bolted to metal enclosure to provide continuous electrical ground.
ii.
Enclosure
The metal enclosures shall be made from suitable thickness (usually between 1114 gauge)
Sheet steel, Aluminum or Stainless steel. Aluminium & Stainless steel being nonmagnetic
materials results in low losses due to electromagnetic induction. Hence the enclosure size is
less for Aluminium & Stainless steel in comparison to MS sheets. MS sheet enclosures are
used up to current rating of 2500A and Aluminium or stainless steel sheet enclosures are in
practice for ratings more than 2500A. Galvanized Iron (GI) sheet enclosures can also be used
in place of MS enclosure particularly for outdoor application.
Outdoor enclosures shall be additionally provided with rain canopy for water ingress
protection. Enclosures shall be finished with bakedon polyester powder coat paint that
results in a uniform thickness and glossable to withstand harsh environments. Standard
color is ANSI61 light gray, special colors shall also be used if required. All enclosures should
have removable covers secured with bolts for easy access to the joints for periodic
inspection. Flexible joints shall be supplied in all straight bus runs at intervals of
approximately 50 feet to allow for expansion when conductors are energized and carrying
rated current. Minimum two numbers of space heaters with thermostats shall be provided
to prevent moisture condensation and maintain cubicle temperature 5 C above the
ambient. The busduct shall be provided with silica gel breathers, in all sections.
c) Basic design parameters:

Following are the basic design parameters of an air insulated nonsegregated phase busduct:
x Conductor material e.g. Aluminium or Copper
x Conductor type e.g. Rectangular bar, channel or pipe
x Normal current rating e.g. 1200, 1600, 2000, 2500, 3200, 4000 Amps. Etc.
x Rated short circuit current e.g. 40kA for 1 Sec
x Rated voltage e.g. 415, 460, 3300, 6600, 11000, 22000, 33000 etc.
x Rated frequency e.g. 50 or 60 Hz
x Rated Basic Insulation Level (BIL) e.g. BIL for 11kV system is 12/28/75 kV, where
12kV
: Highest system voltage
28kV
: Power frequency withstand voltage
75kV
: Impulse withstand voltage
x Permissible temperature rise of conductor & enclosure e.g. above 50C ambient
Plain electrolytic copper : 35C
Plain Aluminium
: 35C
Hotspot
: 40C
Enclosure
: 20C
x Enclosure material e.g. MS, SS, Aluminium sheet or GI
d) Components of a busduct:
Following are the components of an air insulated nonsegregated phase bus ducts
x Conductor or Busbar
x Busbar insulation i.e. PVC sleeves or Epoxy paint
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x
x
x
x
x
x
x
x
x
x
Support Insulator e.g. FRP sheets, Post insulator Epoxy or Porcelain

Enclosure
Silica gel breather & drain plugs
Anticondensing heater
Marshalling box for heater & CT (if used)
Misc hardware i.e. Nuts & bolts for jointing of bus bars & enclosure
Flexible links for connecting busduct with equipment e.g. Tin coated copper flexible links
Bends, disconnecting links (if required)
Rain canopy for outdoor installation
Wall frame assembly & support structure
e) Design calculation of busduct:

Design & calculate the cost of Busduct of following specifications:
3000A, 3 415V, 50Hz, 40kA for 1 sec

Length 15 Meters
Assumptions: We assume
x
x
x
x
x
x
x
x
x
x
Conductor of Busbar is Aluminium

PVC sleeves are used for busbar insulation
Support insulators are FRP sheets
Enclosure is of MS sheet of 2 mm thickness
Single earth bus of 50x6 mm Al shall be provided
1 silica gel breather is used at every 6 meters length of busduct
1 anti condensation heater is used at every 6 meters length of busduct
1 marshalling box for heater connection is used at every 6 meters length of busduct
There is no bend in the busduct
Busduct is used inside, hence rain canopy is not required
Calculation of size of components:

i.
Aluminium bus bars

Lets
Current density of Aluminium for open busbar,
Derating factor for Busbar, indoor, k*
Density of Aluminium for bars
Adjusted current density of Al bus bar conductor,
?Required cross sectional area of busbar
= 1.2 A/mm2
= 0.65
= 2.7 gms/cm3
= 1.2 x 0.65
= 0.78 A/mm2
= (Rated current) / (Current density)
= 3000 / 0.78
= 3846 mm2
We choose busbar of 2nos of 200mm x 10mm size.

Hence actual cross sectional area of busbar
= 2 x 200 x 10 = 4000 mm2
* Refer Appendix 1: Derating of busbars.
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Design validation
We need to check if the busbars chosen
x Safely dissipates the generated heat (copper loss) and hence the conductor
temperature rise is within limit i.e. < conductor material softening temperature.
x Voltage drop, at receiving end, is within limits
x Mechanical strength Is more than the strain developed during short circuit
Temperature rise of conductor
Short circuit current
Time duration
Cross section of busbar
Material of busbar
= 40kA
= 1 sec
= 4000 mm2
= Aluminium
Formula:#
C * (Isc/a)2 * (1+) * 102 * t
Where,
T = Final conductor temperature after fault, in qC
C = Material constant i.e. 0.54 for Copper, 1.17 for Aluminium
Isc = Short circuit Current, in Amps
a = Cross section area of conductor, in mm2
= Temperature coefficient of resistivity at 20qC
0.00393 for Copper
0.04003 for Aluminium (EIEM)
0.00364 for Aluminium alloy (E9IE WP)
T = Initial conductor temperature before fault, in qC i.e. Ambient + permissible
temperature rise e.g. in our case its 50+35 = 85qC
t = Duration of fault, in sec
# Ref: Electrical substation Engineering & Practice Handbook by S S Rao.
Calculation:
T
=
=
1.17 * (40000/4000)2 * (1 + 0.00364 * 85) * 102 * 1

1.5 qC
Maximum temperature after flow of short circuit current = 85 + 1.5 = 86.5qC, which is
lower than the hot spot temperature 50+40=90qC and threshold temperature of 160qC,
above which Aluminium becomes soft and looses its mechanical strength.
If the temperature rise is not within limit, the busbar size needs to be increased.
Voltage drop
Rated current
Material of busbar
Maximum permissible voltage drop
Pankaj Kumar
= 3000 A
= 4000 mm2
= Aluminium
< 2%
Page 10 of 27
Formula:
The busbar reactance is not normally sufficiently large to affect the total reactance of a
power system and hence is not included in the calculations when establishing the short
circuit currents and reactive volt drops within a power system. The voltage drop is
usually calculated from the circuit current & resistance of conductor.
Vd = IRac
= IRdc* k
= I * ( * L/a) * k
Where,
Vd = Voltage drop / phase
I = Rated current
Rdc = DC Resistance of conductor / phase
Rac = AC Resistance of conductor / phase
k = Correction factor for Skin & Proximity effect e.g. usually 1.2
= Resistivity, in mm2/m
For Aluminium :
0.0287 at 0C, 0.034 at 75C
For Copper
:
0.01724 at 0C, 0.021 at 75C
L = Conductor length, in m, i.e. 15 Meters in our case
a = Cross section area of conductor/phase, in mm2
Calculation:
Vd =
=
=
I * ( * L/a) * 1.2
3000 * (0.034 * 15 / 4000) * 1.2
0.459 V
Voltage drop in %
Vd (%) =
=
=
Vd * 100 / (VL / 3)
0.459 * 100 / (415 / 3)
0.19 %
The voltage drop is less than maximum permissible voltage drop i.e. 2%.
Hence the size of busbar conductor is safe.
Mechanical strength of busbar
The force occurs at the peak of first major loop of short circuit current. The force
between main conductors on a span (distance between two insulating supports) length
of busbar can be found out as below:
Formula:#
F
Where,
F =
idyn =
Pankaj Kumar
2.04 * (idyn)2 * (D / r) * 102
Force between conductors, in Kgf

Peak value of short circuit current per conductor, in kA
idyn = 2.5 times of short circuit withstand current, for 50 Hz system
idyn per conductor = idyn / Number of conductors per phase
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Span between insulators support, in cm

We consider 1 meter span i.e. 100 cm
Distance between neighboring conductors (Phases), in cm
# Ref: Electrical substation Engineering & Practice Handbook by S S Rao.
Calculation:
Force between conductors, F
=
=
=
2.04 x (40 x 2.5/2)2 x (100 / 17) x 102

300 Kg
294.2 daN *
* 1 daN (decaNewton) = 1.01972 Kg

The strain developed in busbar, due to bending moment by force occurred during short
circuit, can be found as below:
Formula:

Where,
F =
L =
I/V =
(F * L / 12) * [1 / (I / V)]
Force between conductors, in daN

Span between insulators support, in cm
We have consider 1 meter span i.e. 100 cm
Modulus of Inertia, in cm3
Modulus of Inertia can be calculated as below (refer Appendix 4 for details):
Pankaj Kumar
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I/v =
=
=
=
2 * [{(b * a3) / 12} + S * d2] / (1.5 * a)

2 x [{(200 x 103) / 12} + (200 x 10) x 102] / (1.5 x 10)
433333 / 15 mm3
28.89 cm3
Calculation:
Strain
=
=
=
(F * L / 12) * [1 / (I / V)]
(294.2 x 100 / 12) x (1/28.89) daN/cm2
84.86 daN/cm2
The maximum fibre strain for Aluminium is 1056 daN/cm.

As the strain developed during short circuit is less than the maximum permissible strain,
the considered busbar size is safe.
ii.
MS sheet for enclosure
As per IS 5578 & 11353,

Minimum gap required between Phases, f = 19 mm
Minimum gap required between Phase & Earth (Enclosure), g = 16 mm
We consider,
Minimum gap required between Phases, f = 25 mm
Minimum gap required between Phase & Earth (Enclosure), g = 20 mm
From calculations in (i), Busbar width, a = 200 mm & thickness, b = 10 mm
Minimum required width of enclosure, W
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= 2 x (t + g + d + e)
= 2 x [t + g + (f + 3b) + 1.5 b]
= 2 x (t + g + f + 4.5b)
= 2 x (2 + 20 + 25 + 4.5 x 10)
= 184 mm
Page 13 of 27
Minimum required height of enclosure, H
= 2 x (t + j + h) + (a 2c)
= 2 x (2 + 25 + 100) + 200 2 x 20
= 414 mm
Considering dissipation of heat generated, supporting systems, rectangular shape etc.,

we take the dimensions as below:
Width of enclosure, W
Height of enclosure, H
= 600 mm
= 450 mm
Design validation
We need to check if the temperature rise of enclosure chosen is within the limit i.e. its
surface area is sufficient to dissipate the generated heat during normal situations.
Temperature rise of enclosure
Maximum rated current
Material of busbar
= 3000 A
= 4000 mm2
= Aluminium
We will first calculate the heat/copper losses occurred in conductor and then the
temperature rise of enclosure due to this heat. The walls of the enclosure dissipate the
heat by both radiation & convection.
Formula Copper/heat loss generated:
Pc = I2Rac
= ( * a)2 * ( * L / a) * 1.2
= 2 * * L * a * 1.2
Pi =
Pc * 15% = 0.15 * Pc
P = 3 * (Pc + Pi)
= 3 * (Pc + 0.15Pc)
= 3.45 Pc
Where,
Pc = Copper loss in conductor / phase, in Watt
Pi = Stray losses in enclosure due to one phase, in Watt
I = Rated current, in Amps
R = Resistance of conductor, in Ohm
= Current density, in A/mm2
= Resistivity, in m
For Aluminium :
0.0287 x 106 at 0C, 0.034 x 106 at 75C
For Copper
:
0.01724 x 106 at 0C, 0.021 x 106 at 75C
L = Conductor length, in m
a = Cross section area of conductor/phase, in mm2
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Formula Heat dissipation / Temperature rise:#
T =
St =
P / ( * St)
P / ( * T)
Where,
T = Temperature rise of enclosure from ambient in qC e.g. 20qC
P = Losses in bus conductor & enclosure, in Watt
= Specific heat dissipation in Watt/m2
12.5 W/m2 for naturally cooled MS surface. 6.0 W/m2 by Radiation & 6.5
W/m2 by convection.
20 W/m2 for forced cooled surface
St = Heat dissipating surface area
# Ref: Electrical machine design Handbook by AK Sawney & Chakrabarti.
Calculation:
Copper loss per unit length/phase, Pc
= 2 * * L * a * 1.2
= (0.78)2 * 0.034 * 106 * 103 * 1000 *
4000 * 1.2
= 99.3 Watt
Total loss per unit length of conductors, P
= 3.45 * Pc
= 342.5 Watt
Surface required for dissipation of heat loss, St = P / ( * T)

= 342.5 / (12.5 * 20)
= 1.37 m2
Actual heat dissipating area of enclosure
= 2 * (Length + Width) * Height

= 2 *(1000 + 600) * 450
= 1,440,000 mm2
= 1.44 m2
As the heat dissipation surface area of considered enclosure is more than required area,
the temperature rise will be less than specified. Hence the size of enclosure is adequate.
The busbar arrangement can be as below:
W =
2 x (t + g + f + 4.5b)
Let,
=
? W =
600 =
g =
f =
e =
d =
Pankaj Kumar
2 x (2 + 2 x g + 4.5 x 10)
4g + 49
137.75 mm
137.75 mm
1.5b = 15 mm
f + 3b = 137.75 + 3 x 10
167.75 mm
Page 15 of 27
iii.
FRP sheet for support insulators

Number of Busbar/Phase
= 2 numbers 200x10 mm
?Busbar support size (L x B x H), in mm

= (Width of enclosure 2 x 5 mm) x
Available standard width x standard thickness of FRP sheet
= (600 10) x 200 x 8
= 590 x 200 x 8
Design validation
We need to check if the FRP sheet insulator chosen withstand the electrodynamics
forces of busbar during flow of short circuit currents.
We have already found out the force between main conductors due to short circuit:
Force between conductors, F
= 300 Kg/m
Force acting on FRP insulator, F1
= F x Span
= 300 Kg/m x 1 m
= 300 Kgs
Area of contact between busbar & FRP plate is Groove depth x Thickness x No of
supports
Now,
Groove depth = 20 mm
Thickness
= 8 mm
No of supports = 2
Area of contact between busbar & FRP plate
= 20 x 8 x 2
= 320 mm2
Shear strength of standard FRP plate
= 6.12 Kg/mm2
Shear strength of considered FRP plate
= 6.12 Kg/mm2 x 320 mm

= 1958.4 Kg
Shear strength of the considered FRP plate i.e. 1958 Kg, is more than force on it i.e. 300
Kg. Hence it is safe.
f)
Other design validations:

We also have to check that the period of vibration to the busbars themselves is not resonant
with the system current frequency.
The natural frequency of horizontal busbar, fixed at both ends, can be found from below
formula (referred from www.copperinfo.co.uk\busbars)
fn =
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18.04 /
Page 16 of 27
Where,
fn = Natural frequency of busbar, Hz
= Maximum deflection, mm

5w * L4 / (384 * E * I)
Where,
w = Weight per unit length of busbar, N/mm (Aluminium 2.7 x 103 N/mm)
L = Busbar length between supports, mm = 1000 mm
E = Modulus of elasticity (Aluminium 71 x 103 N/mm2)
I = Moment of inertia of busbar section, mm4
= 2 * [{(b * a3) / 12} + S * d2]
= 433333 mm4

=
=
5 x (2 x 2.7 x 103) x (1000)4 / (384 x 71 x 103 x 433333)

2.286 x 103 mm
? fn
=
=
18.04 / (2.286 x 103)

377 Hz
The frequency of current flowing in busbar is 50 Hz. For harmonic currents, it will be in multiple
of fundamental frequency 50Hz. The busbar natural frequency is 377 Hz which is far away than
the normal frequency of current. Hence the busbar chosen is safe.
g) Calculation of weights of raw materials:
i.
Aluminium bus bars

Cross sectional area of busbar/Phase
Volume of unit length (1 meter) of busbar/phase
Weight of unit length of busbar for all 3 phases
Weight of Earthing bus for unit length

Total weight of aluminium busbars for unit length
= 2 x 200 x 10 = 4000 mm2

= 4000 mm2 x 1000 mm
= 4000 Cm3
= 3 x Volume x Density
= 3 x 4000 x 2.7
= 32.4 Kgs
= 1 x 50 x 6 x 2.7
= 0.81 Kgs
= 32.4 + 0.81 = 33.21 Kgs
Considering wastage of 5%, total weight of busbars

35 Kgs/m
ii.
MS sheet for enclosure

Size of enclosure,
Width of enclosure, W
Height of enclosure, H
Thickness of sheet, t
Cross sectional area of enclosure
Volume of enclosure per unit length ( 1 meter)

Pankaj Kumar
= 600 mm
= 450 mm
= 2 mm
= 2 t * (W + H + 2t)
= 2 * 2 * (600 + 450 + 2 * 2)
= 4216 mm2
= 4216 * 1000 mm3
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Weight of enclosure, per unit length
Considering wastage of 5%, weight of enclosure
iii.
=
=
=
=
4216 cm3
Volume * Density
4216 cm3 * 7.81 gms/cm3
32.9 Kgs
35 Kgs/m
FRP sheet for support insulators

Size of FRP support insulator,
Width of support insulator, w
Height of support insulator, j
Thickness of sheet, t
Number of insulators per unit length
Cross sectional area of FRP sheet
Volume of one FRP insulator sheet
Weight of FRP insulator sheet per unit length
Considering wastage, total weight of FRP sheet
= 600 10 = 590 mm
= 100 mm
= 8 mm
=2
=wxj
= 590 x 100
= 59000 mm2 x 8 mm
= 472 cm3
= 2 x Volume x Density
= 2 x 472 x 1.799 gms
= 1.699 Kg
1.8 Kg/m
h) Calculation of cost of busduct:

Cost of busduct consists of
x
x
x
x
x
Raw material cost

Other components cost i.e. heater, thermostat, silica gel breather etc.
Jointing hardware cost i.e. nuts, bolts washer etc.
Overheads i.e. manufacturing expenses
Manufacturers Profit
Let,
Rate of Aluminium + busbar preparation work
Rate of MS sheet + fabrication + painting
Rate of FRP sheet + its preparation etc.
Rate of one anticondensing heater + thermostat
Rate of marshalling box (JB) for heater connection
Rate of Silica gel breather assembly
Misc hardware cost
Manufacturing overheads + Labour charges
Manufacturers Profit
Pankaj Kumar
= 145 Rs/Kg
= 75 Rs/Kg
= 500 Rs/Kg
= 2000 Rs/set
= 1500 Rs/pc
= 1500 Rs/pc
= 10% of basic material cost
= 10% of total material cost
= 15% of total cost
Page 18 of 27
i.
Cost of raw materials

Cost of raw material
= Length of busduct * Cost of raw

material/meter
Cost of raw material per meter
= Weight * rate
Busbar cost Rs/meter
= 35 Kg x 145 Rs/Kg
= 5,075 /
Enclosure cost Rs/meter
= 35 Kg x 75 Rs/Kg
= 2,625 /
FRP insulator sheet cost Rs/meter
= 1.8 Kg x 500 Rs/Kg

= 900 /
Cost of raw material, Rs/meter
= 5,075 + 2,625 + 900

= 8,600 /
Cost of raw material for 15 meters length of busduct, A Rs = 15 * 8,600

= 129,000 /
ii.
Cost of miscellaneous hardware & overheads

Cost of misc hardware @ 10% of cost of raw mat., B = 12,900 /
iii.
Pankaj Kumar
Material cost, C = A + B
= 141,900 /
Cost of overheads @ 10% of material cost, D
= 14,190 /
Total material cost, E = C + D
= 156,090 /
Cost of other components

Required number of heater + thermostat
Required number of JB for heaters connection
Required number of Silicagel breather
= 15 / 6 = 2
= 15 / 6 = 2
= 15 / 6 = 2
Cost of above components, F
= 2 x (2,000 + 1,500 + 1,500)

= 10,000 /
iv.
Manufacturers profit, G
= 15% of (E + F)
= 24,913 /
v.
Total cost of Busduct of 15 meters length
= E + F +G
= 191,003 /
192,000 /
Page 19 of 27
i)
Cost model MS Excel:
Bus Ducts - Cost Model

Inputs
Busbar material
Enclosure material
Rate of Aluminium
Rate of Copper
Rate of steel HR Sheets for Enclosure
Rate of FRP sheets for support insulators
Current rating Amp
TPN or TP
Enclosure width
Enclosure height
Enclosure sheet thickness
FRP sheet insulator width
FRP sheet insulator height
FRP sheet insulator thickness
Busbar details
Width
Thickness
No. of Runs ( Qty / Ph )
Earthbus Width
Earthbus Thickness
No. of earthbus runs
Current density of Al busbar
Current density of Cu busbar
Wastage in busbar
Wastage in enclosure
Misc hardware cost
Labour + Overheads
Profit
Density of Aluminium
Density of Copper
Density of Sheet steel
Pankaj Kumar
Aluminium
Sheet steel
110
200
30
500
3000
3
600
450
2
590
100
8
200
10
2
50
6
1
0.77
1.2
5.0%
5.0%
10.0%
10.0%
15.0%
2.7
8.89
7.81
Rs/Kg
Rs/Kg
Rs/Kg
Rs/Kg
Amp
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
Amp/mm^2
Amp/mm^2
Gms/Cm3
Gms/Cm3
Gms/Cm3
Page 20 of 27
Outputs
Actual current rating of busbar
3,080
Amps
Current density of busbar material

Density of busbar material
Density of enclosure material
Rate of busbar material including fabrication
Rate of enclosure material including fabrication, painting
0.77
2.70
7.81
145.00
75.00
Gms/Cm3
Gms/Cm3
Gms/Cm3
Rs/Kg
Rs/Kg
Busbar X-section mm^2

Weight of busbar per m
Cost of busbar per m
Enclosure weight per m
Cost of enclosure (inclussive painting) per m
Insulator Plate Wt
Cost of Insulator plates per m
Misc hardware cost i.e. Nuts, bolts, gaskets etc
Total material cost
Labour cost and overheads
Total manufacturing cost
Profit
12,300
34.87
5,056
34.6
2,593
0.89
892
854
9,395
939
10,334
1,550
mm2
Kg/m
Rs/m
Kg/m
Rs/m
Kg/m
Rs/m
Rs/m
Rs/m
Rs/m
Rs/m
Rs/m
Indicative price per meter length
11,885
Rs/m
Pankaj Kumar
Page 21 of 27
7. Final Results
x
Various types of bus ducts were studied
3 phase, 415V, 50Hz, 3000A indoor nonsegregated phase busduct was designed and the design
parameters were validated by various calculation methodologies
Detailed costing was done for above busduct
Cost module for above bus duct was made in MS Excel software and validated by collecting an
actual offer from one manufacturer.
8. Conclusion
x
The busduct design details, given in this project report, can be referred by the practicing
design/project engineers
This module can be used for cost approximation of indoor type nonsegregated phase LV & MV
bus ducts up to 4000A rating
This is very handy and elaborative design & cost approximation module for bus duct
9. Scope of Future Study

Similar design & cost module can me developed for
x
Segregated phase bus ducts
Isolated phase bus ducts
Pankaj Kumar
Page 22 of 27
Appendix 1: Derating factors for busbar

Derating factor for bus bar, k
k1 * k2 * k3 * k4 * k5 * k6
Where,
x
Coefficient k1 is a function of the number of bar strips per phase for:

For 1 bar,
2 or 3 bars,
e/a
k1 for 2 bars
k1 for 2 bars
k1 = 1
see table below:
0.05
1.63
2.40
0.06
1.73
2.45
0.08
1.76
2.50
0.10
1.80
2.55
0.12
1.83
2.60
Coefficient k2 is a function of surface condition of the busbars:

Bare: k2 = 1
Painted: k2 = 1.15
Coefficient k3 is a function of the position of the bars:

Edgemounted bars: k3 = 1
1 bar basemounted: k3 = 0.95
Several basemounted bars: k3 = 0.75
Coefficient k4 is a function of the place where the bars are installed:

Calm indoor atmosphere: k4 = 1
Calm outdoor atmosphere: k4 = 1.2
Bars in nonventilated ducting: k4 = 0.80
Coefficient k5 is a function of the artificial ventilation:

Without artificial ventilation: k5 = 1
With artificial ventilation: k5 > 1
Coefficient k6 is a function of the type of current:
0.14
1.85
2.63
0.16
1.87
2.65
0.18
1.89
2.68
0.20
1.91
2.70
For alternating current of frequency 60 Hz, k6 is a function of the number of bars n per phase and
of their spacing.
The value of k6 for spacing equal to the thickness of the bars:
n
1
2
3
k6
1
1
0.98
Pankaj Kumar
Page 23 of 27
Appendix 2: Standard Aluminium busbar sizes and their Ampacity table
Aluminum Bus Bar Amperes for 6101T61 Alloy 57% IACS Conductivity Chart Below
Bar Sizes
1 Bar
2 Bars
3 Bars
4 Bars
(Inches)
DC
60 Hz AC
DC
60 Hz AC
DC
60 Hz AC
DC
60 Hz AC
1/4 x 1
308
308
607
601
605
887
1203
1168
1/4 x 1 1/2
430
429
833
817
1235
1194
1637
1561
1/4 x 2
549
545
1051
1021
1552
1480
2053
1915
1/4 x 3
780
768
1472
1410
2162
2000
2851
2530
1/4 x 4
1005
980
1878
1760
2749
2462
3619
3081
1/4 x 5
1225
1184
2275
2092
3321
2905
4365
3625
1/4 x 6
1443
1381
2665
2413
3881
3338
5095
4146
1/4 x 7
1870
1760
3427
3034
4974
4183
6517
5152
3/8 x 2
691
678
1340
1278
1989
1831
2638
2332
3/8 x 3
974
941
1857
1709
2739
2384
3620
2946
3/8 x 4
1249
1191
2356
2099
3460
2893
4563
3574
3/8 x 5
1519
1429
2842
2483
4162
3387
5479
4178
3/8 x 6
1785
1657
3320
2847
4848
3857
6375
4765
3/8 x 8
2308
2098
4253
3569
6188
4774
8119
5875
3/8 x 10
3822
2534
5165
4289
7493
5632
9817
6941
1/2 x 3
1145
1074
2205
1991
3265
2742
4324
3297
1/2 x 4
1462
1369
2782
2416
4100
3264
5417
3940
1/2 x 5
1774
1634
3345
2828
4912
3778
6477
4580
1/2 x 6
2081
1892
3897
3230
5706
4284
7514
5210
1/2 x 8
2685
2393
4975
4014
7255
5276
9531
6246
1/2 x 10
3278
2880
6209
4779
8763
6256
1149
7579
Note:
i.
Ratings are based on 30C rise over 40C ambient in still but confined air (e=0.35), corresponding to usual
indoor temperature.
ii.
Space between bars is assumed equal bar thickness.
iii.
For AC phase spacings less than 18 inches an allowance for proximity effect must be made.
Pankaj Kumar
Page 24 of 27
Appendix 3: Indoor busbars Minimum clearances
Table 3.1 Indoor busbars : Open or enclosed Clearances for

voltages up to 33kV
Rated
voltage
Minimum clearance to
Earth
Minimum clearance
between Phases
rms
Open
Enclosed
Open
Enclosed
kV
mm
mm
mm
mm
0.415
19
16
26
19
0.6
26
19
32
19
3.3
51
51
51
51
11
77
77
127
127
15
102
102
165
165
22
140
140
242
242
33
223
223
356
356
Table 3.2 Indoor busbars : Open or enclosed Creep age distances
Rated voltage
Pankaj Kumar
Minimum clearance to Earth
rms
Phase to Earth
Phase to Phase
kV
cm
cm
6.6
15
17.5
11
17.5
30
22
25
38
33
33
45
45
42
53
66
63
77
110
106
132
132
125
156
220
178
225
400
354
400
Page 25 of 27
Appendix 4: Modulus of Inertia between busbars

x
Modulus of inertia One bar per phase
Moment of Inertia, I
= (b * a3) / 12
Modulus of Inertia, I/v = [(b * a3) / 12] / (a / 2)
= (b * a2) / 6
Modulus of inertia Two bars per phase
Moment of Inertia, I
= 2 * [{(b * a3) / 12} + S * d2]
Modulus of Inertia, I/v = 2 * [{(b * a3) / 12} + S * d2] / (1.5 * a)

Where, S = Busbar cross section of one bar (in cm2)
Standard table for cross section area S, linear mass m, moment of inertia I & modulus of inertia I/V
Pankaj Kumar
Page 26 of 27
References:
1. Electrical substation Engineering & Practice Handbook by S S Rao
2. Electrical machine design Handbook by AK Sawney & Chakrabarti
3. Website: http://www.copperinfo.co.uk/busbars
4. Website: http://en.wikipedia.org/wiki/Density
5. Website: http://www.fiberbond.com/docs/FRPdesign.pdf
6. Siemens, BCH & Schneider busduct catalogues
Pankaj Kumar
Page 27 of 27

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Evaluation, Estimation & Costing of Bus ducts

Project report/Technical paper

Pankaj Kumar Rajput

Evaluation, Estimation & Costing of Bus ducts

Project report/Technical paper

Title of the Project ....................................................................................................................................... 3

Objectives of the study ................................................................................................................................ 3

Methodology used for carrying out the study ............................................................................................ 3

Statement of the Problem ........................................................................................................................... 3

Input data/Structure/Questionnaire ........................................................................................................... 3

Type of busbars: ...................................................................................................................................... 4

Busduct design & costing: ....................................................................................................................... 7

Introduction to busduct design ........................................................................................................... 7

Basic design parameters: ..................................................................................................................... 8

Components of a busduct: .................................................................................................................. 8

Design calculation of busduct:............................................................................................................. 9

Aluminium bus bars ......................................................................................................................... 9

MS sheet for enclosure.................................................................................................................. 13

FRP sheet for support insulators ................................................................................................... 16

Other design validations: ................................................................................................................... 16

Calculation of weights of raw materials: ........................................................................................... 17

Aluminium bus bars ....................................................................................................................... 17

MS sheet for enclosure.................................................................................................................. 17

FRP sheet for support insulators ................................................................................................... 18

Calculation of cost of busduct: .......................................................................................................... 18

Cost model MS Excel: ..................................................................................................................... 20

Final Results ............................................................................................................................................... 22

Scope of Future Study ............................................................................................................................... 22

Appendix 1: Derating factors for busbar ........................................................................................................... 23

Evaluation, Estimation & Costing of Bus ducts

Project report/Technical paper

Study of types & design parameters of Busbars

3. Methodology used for carrying out the study

Study of various types of busbars from technical books & internet

4. Statement of the Problem

Find out the details of various types of Busbars & Busducts

Evaluation, Estimation & Costing of Bus ducts

Project report/Technical paper

Evaluation, Estimation & Costing of Bus ducts

Project report/Technical paper

5) Based on insulation between the phases, Busducts are of following types:

Pictorial cross sectional view of nonsegregated busduct

Evaluation, Estimation & Costing of Bus ducts

Project report/Technical paper

Pictorial view of segregated phase busduct

Low range Typical 1 insulator

Evaluation, Estimation & Costing of Bus ducts

Project report/Technical paper

B. Busduct design & costing:

Evaluation, Estimation & Costing of Bus ducts

Project report/Technical paper

c) Basic design parameters:

Evaluation, Estimation & Costing of Bus ducts

Project report/Technical paper

Support Insulator e.g. FRP sheets, Post insulator Epoxy or Porcelain

e) Design calculation of busduct:

3000A, 3 415V, 50Hz, 40kA for 1 sec

Conductor of Busbar is Aluminium

Calculation of size of components:

Aluminium bus bars

We choose busbar of 2nos of 200mm x 10mm size.

Evaluation, Estimation & Costing of Bus ducts

Project report/Technical paper

Surface required for dissipation of heat loss, St = P / ( * T)