CLIENT: - M/S PEPSICO HOLDING PVT. LTD. PROJECT: - AQUFINA (PHASE-III) PLANT AT MAHUL- MUMBAI.

Bus Bar Calculation for Main LT Panel A. Bus Bar size calculation for 3200A Rating Panel: -

CONDITIONS Rating Current: System: Fault Level: Operation Temp: CONSIDERATION Enclosure size: Bus bar Size: Bus bar material: CALCULATION
1.

3200Amp. 415Vac, TPN, 50Hz. 50KA. For 1 Sec. 40C rise over 45C ambient.

1400mm. wide X 400mm. height 2:200x10 per Ph., 1:200x10 for Neutral. Electrolytic gr. Al. (IS 63401/AA6101)

AC Current rating for Dual Al. Flats 200x10mm considered = 4750Amp.

(As per Table 8.4 as INDAL hand book)

2.

Ambient correction factor (k1) 45C rise over 35C (ambient) = .88

(As per Table 5 as INDAL hand book)

If ambient Temp. 45C instead of 35C than De-rating Factor = 1- C x

= Temp difference = 45C - 35C = 10 = Resistance-Temp. Coefficient for Al. Bus= 0.00403

k1A

= 1-10 x 0.00403 = 0.96

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3.

Enclosure correction factor (k2) ratio of total conductor bus bar crosssection to enclosure cross-section. (3 x 2 x 200 x 10) x 100 --------------------------------= 2% 1400 x 400 De-rating factor for enclosure = 0.82
(As per Table 5 as INDAL hand book)

4. 5.

Correction factor (k3) for busbar material = 1 Up-rating factor (k4) for PVC Sleeving bus bar = 1

6.

Total Combined De-Rating factor

= k1xK1Axk2xk3xk4 = 0.88 x 0.96 x 0.82 x 1 x 1 = 0.693

So, actual rating of considered busbar = 4750 x 0.693 = 3291Amp.

Conclusion: It means 2:200x10mm Al. Bus Bar is much sufficient for 3200A Rating as per actual operating conditions.

B.

Minimum Conductor size for Stand 50KA Fault: While considering short circuit condition, assuming a steady state average temperature of 75C and final temperature of 160C then required bus section: CALCULATION: (As per table 17)

Let

f I A T Isc

=Final conductor temp after the fault = Initial conductor temp before the fault = Cross sectional area of conductor (Sq. inch) = Duration of fault (sec.) = Short circuit current A f + 258

= 160C. = 75C. =? = 1 Sec. = 50KA.

Or

Isc = 14 x 10 ------

log10 --------------- I + 258

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Or

A=

Isc x T --------------------------------------------- f + 258 14 x 10

log10 --------------- I + 258

50,000 x 1 Or A= ---------------------------------------------- = 0.93 in 160 + 258 14 x 10

log10 ---------------75 + 258

Or

A=

600 mm. Considered bus section = 2x200x10 = 4000mm.

Conclusion: It means 2:200x10mm Al. Bus Bar is much sufficient for stand 50KA Fault Current for 1Sec. C. TEMPERATURE CONDUCTORS: RISE CALCULATION OF

Max. Temperature at full Load condition: i.e. When 3200Amp. Flows thru steady state temperature of 45 C. Full Load Current T max = Ambient X ------------------------------------------------------- X Allow T rise Actual Current Rating of used Conductors 45 + (3200 / 3291) x 40 = 82.8C which is within the limit of 85C [45+40].

Summary: Hence the designed bus bar for Main Panel is OK & within the safe limit.
Reference: INDAL hand book And IS: 8623 (Part 1) of 1993.

MILESTONES SWITCHGEARS PVT. LTD.

Tel: (0124) 4002970, 5002971, Telefax: (0124) 4002973.

Bus Bar Calculation for Bus Duct A. Bus Bar size calculation for 3200A Rating Bus Duct: CONDITIONS Rating Current: System: Fault Level: Operation Temp: CONSIDERATION Enclosure size: Bus bar Size: Bus bar material: CALCULATION
1.

3200Amp. 415Vac, TPN, 50Hz. 50KA. For 1 Sec. 40C rise over 45C ambient.

750mm. wide X 450mm. height 2:200x10 per Ph., 1:200x10 for Neutral. Electrolytic gr. Al. (IS 63401/AA6101)

AC Current rating for Dual Al. Flats 200x10mm considered = 4750Amp. (As per Table 8.4 as INDAL hand book)

2.

Ambient correction factor (k1) 45C rise over 35C (ambient) = .88

(As per Table 5 as INDAL hand book)

If ambient Temp. 45C instead of 35C than De-rating Factor = 1- C x

= Temp difference = 45C - 35C = 10 = Resistance-Temp. Coefficient for Al. Bus= 0.00403

k1A

= 1-10 x 0.00403 = 0.96

MILESTONES SWITCHGEARS PVT. LTD.

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3.

Enclosure correction factor (k2) ratio of total conductor bus bar crosssection to enclosure cross-section. (3 x 2 x 200 x 10) x 100 --------------------------------= 3.5% 750 x 450 De-rating factor for enclosure = 0.78
(As per Table 5 as INDAL hand book)

4. 5.

Correction factor (k3) for bus bar material = 1 Up-rating factor (k4) for Black Matt Painted bus bar = 1.2

6. Total Combined De-Rating factor = k1xK1Axk2xk3xk4 = 0.88 x 0.96 x 0.78 x 1 x 1.2 = 0.79 So, actual rating of considered bus bar = 4750 x 0.79 = 3752Amp.

Conclusion: It means 2:200x10mm Al. Bus Bar is much sufficient for 3200A Rating as per actual operating conditions. Summary: Hence the designed bus bar for Bus Duct is OK & within the safe limit.
Reference: INDAL hand book And IS: 8623 (Part 1) of 1993.

Bus Bar Calculation for Other Panels [Main Bus]

Sl. No. 1.0 2.0 3.0 Used Current Rating in Amp. 1600Amp . 800Amp. 630Amp. Current Rating as per INDALHand Book Table No. 8.4 in Amp. 2650Amp. 1565Amp. 1250Amp. Max. [Approx] Total DeRating Factor 0.7 0.7 0.7 Actual Current Rating 1855Amp 1095Amp 875Amp

Used Bus Bar Size: 2x100x10 For Ph. 1x100x10 For N. 100x10 For Ph. 100x6 For N. 80x10 For Ph. 80x6 For N.

MILESTONES SWITCHGEARS PVT. LTD.

Tel: (0124) 4002970, 5002971, Telefax: (0124) 4002973.