DESIGN CALCULATIONS

FOR
DESIGN OF 11 kV, 1100A SEGREGATED PHASE BUSDUCT
AND ACCESSORIES
An Interconnection between
LA, SC, PT, & CT Panel &11 kV HT Switch Board

PROJECT:

2 x 15 MW COGEN POWER PLANT

{ INDORAMA PETROCHEMICALS LTD., BUTIBORI, NAGPUR}

CONSULTANT:
M/s. DESEIN PRIVATE LIMITED.,

Contents:
Page 1 of 13

1.

Design Parameters

2.

Thermal Withstand Capability

3.

Evaluated Heat loss of Conductor

4.

Enclosure Temperature Rise

5.

Mechanical Stress Withstand Capability

6.

Voltage Drop Calculations

7.

Reference Documents

Page 2 of 13

Design parameters
1

Nominal System Voltage

11 kV

Rated Voltage

12 kV

BIL Rating.

12 kV / 35 kV / 75 kVP

Encl. Dimension

1196 mm x 400 mm

Encl. Material

3mm Thk. Aluminium

Busbar Material

Copper

Busbar Size

100 x 10 mm

8. Cross Sectional Area

1000 Sq. mm

9. Barrier Material

2mm Thk. Aluminium

10. Short Circuit Current

40 kA.

8. Duration of Short Circuit

3 Sec.

9. Momentary Peak Withstand Current

102 kAp

10. Design Ambient Temperature

500 C

11. Max. Temperature Rise of Conductor Carrying Rated Current -

350 C

12. Max. Temperature Rise of Enclosure

200 C

13. Max. Temperature of Conductor Carrying

3000 C

1100 A

Fault Current
17. Rated Current

Page 3 of 13

Thermal Withstand Capability

Continuous Current Rating
Derating Factors:
Derating Factor of Enclosure :
Conductor to Enclosure Ratio

Conductor Cross Section

Enclosure Cross Section

Ratio =

1000 x 3
1196 x 400

Ratio <

1%

For Indoor Installation

0.65

Derating Factor for Proximity:

Proximity

Phase Spacing (S) Width (a)

Width (a) + Thickness (b)

400 100
100 + 10

2.72

From the Graph Proximity Factor = 1.0

Derating Factor for Temperature Rise:
Temperature Rise of 35 0 C Rise above 50 0 C Ambient

1
2

35
50

0.61

0.61

= 0.805
Derating Factor for Black-Matt finish

1.2

Derating Factor for Non Magnetic Enclosure

1.0

Page 4 of 13

Total De-rating factor

0.65 x 1 x 0.805 x 1.2 x 1

0.6279

AC Current rating as per Copper for Busbar by Copper development Association in Free Air for
above Busbar @ 50 0 C over an ambient of 40 0 C.

2065 A

Rating of busbar for above size conductor

2065 x 0.6279

1296.61 A

Page 5 of 13

Calculation of Short Circuit Rating:

The Cross Section area required for Thermal Withstand capability is given by the formula
A 2
0.051 ---I

(1 + 0.0076 ) - 1

Area of Cross Section required

( Sq. mm )

Isc

Equivalent Short Circuit Current

40

kA (rms)

Short Circuit Duration

03

Max. Permissible Temp. During short circuit -

(300-85 = 215) 0 C

Where A

Second

Therefore

A
0.051 ----40

The Cross section area actually adopted

(1 + 0.0076 x 215 ) - 1

388.69

Sq mm

1000

Sq. mm

Which is more than what is required for Thermal withstand capability

Page 6 of 13

Heat Loss in Conductor

Heat loss in conductor at 85 0 C
Rdc @ 20 0 C =
=
Rdc @ 85 0 C =

3 x 11002 x Rac

l / A
17.2

Micro Ohms / Mt.

Ro { 1 + ( T2 - To ) }

17.2 { 1 + 0.0039 ( 85 - 20 ) }

21.56 Micro Ohms / Mt.

S.E.R Calculation
=

( f/ Rdc ) for 1000 Mts.

50 / 21.56 x 10-3

48.157

From the Graph S.E.R

Rac

= 1.15

1.15 x 21.56

24.79 Micro Ohms / Mt.

Heat loss in conductor at 85 0 C

3 x 11002 x 24.79 x 10-6

89.99 W / Mts.

Total Heat Generated = 89.99 W / Mts.

Page 7 of 13

Enclosure Temperature Rise

Enclosure Height

400 mm

Enclosure Width

1196 mm

Ambient Temp.

50 0 C

Max. Encl. Temp.

70 0 C

emissivity

0.9

Heat Dissipated by Convection

= 2x

7.66 (20)1.25
(400)0.25

x 0.400 +

5.92 (20)1.25

x 1.196

(1196)0.25

= 2 x [ 28.97 + 50.92 ]
Wc

= 159.78 W / Mts.

Heat Dissipated by Radiation

= 5.70 x 10-8 x 0.9 [ (343)4 (323)4 ] x 3.192
Wr

= 484.16 W / Mts.

Total Heat Dissipated = Wc + Wr

= 159.78 + 484.16
= 643.94 W / Mts.

Since the Heat Dissipation Capability is Higher than Heat Generated, the Temperature Rise of
Conductor will be less than 20 0 C

Page 8 of 13

Mechanical Stress Withstand Capability

1. Instantaneous Maximum Short Circuit Force are calculated using the formula
1.42 x 10-7 x (40)2 x 106
Fm

Fm

--------------------------------------0.4
568 Kg / M

2. Steady State Force ( Fs ):

Steady State Force ( Fs )

0.375 x 568

213 Kg / M

3. Steady state force acting on Top of the Insulator ( Cf ) =

Fs x ( H1 + H2 )
H1

H1

- Height of the Insulator

150 mm

H2

- Height of the neutral axis of the

conductor above the Insulator

5 mm

Fs

- Steady State Force

213 Kg / M

213 ( 150 + 5 )
150

Cf =

220 Kg / M

4. Permissible Span of the Support Insulator

C S of Insulator
F.S. x Cf

CS
FS
Cf

960 Kgs
2.5
220 Kg / Mtr.

- Cantilever Strength of Insulator

- Factor of Safety
- Cantilever Force at the Top of Insulator

960
2.5 x 220

Insulator Support Span

1.75 Mts.

Page 9 of 13

Maximum Adopted Support Span

1.75 Mts.

5. Max. Bending Moment

F.S x ( S )2
8

Cf

- Cantilever Force ( Steady State Force )

220 Kg / Mtr.

- Insulator Span

1.75 Mtr.

220 ( 1.75 )2
8

M
6. Max. Fiber Stress

84.21 Kg Mtr.

M
Z

84.21
16.67 x (10)-6

F
Copper permissible limit is

0.50 x 107 Kg / M2

- 245 N / mm2

2.5 x 107

Kg / M2

Hence safe

Page 10 of 13

Voltage Drop Calculations

Rated Current =

1100 A

Rac

24.79 Micro Ohms / Mt.

Reactance Calculation

1.26 x

Phase Spacing (S)

Width (a) + Thickness (b)

1.26 x

400
100 + 10

4.58

From the Graph Reactance

= 57 Micro Ohms / ft.

X = 57 x 3.28
= 186.96 Micro Ohms / Mt.

Voltage Drop at Rated Current at 0.8 P.F = 3 x 1100 x [ (R cos ) + ( X sin ) ] x 10-6
= 3 x 1100 x [ (24.79 x 0.8) + (186.96 x 0.6) ] x 10-6
VD = 0.25 Volts / Mts.

Page 11 of 13

Reference Documents :
a. Copper for Busbar

By Copper Development Association

b. Aluminium for Busbars.

By Mr. A. G. Thomas and Mr. P. J. Rata

Page 12 of 13

Page 13 of 13