MCC Bus Bar Sizing Calculation

1000 A MCC BUSBAR SIZING CALCULATIO
PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

CLIENT M/s. K.P.R. SUGAR MILL LTD
CONSULTANT M/s AVANT GARDE ENGINEERS AND CONSULTANT (P) LTD.
EPC ISGEC HEAVY ENGINEERING LIMITED
CONTRACTOR
Document ID KR11-10302-CLC-001
1 Input Data
1.1 Type of Panel :
1.2 System :
1.3 Rated Voltage :
1.4 degree of Protection :
1.5 Panel Max. Current Rating in Amp (Design) :
Fault Current & Duration (KA RMS Symmetrical

1.6 :
for 1 Sec.)
1.7 Ambient Temperature (Deg. C.) :

1.8 Maximum Bus bar Temperature (Deg. C.) :
1.9 Maximum Enclosure Temperature (Deg. C.) :
1.10 Degree of Protection :
Bus bar Size for Phase :
Bus bar Size for Neutral :
No. of Runs :
1.11
No. of times Interleaved :
Width of Bus Bar in mm :
Thickness of Bus Bar in mm :
1.12 Bus bar cross section for Neutral in Sq.mm
1.13 Cross section of Bus bar Selected in Sq. mm :
1.14 Type of Insulator :
1.15 Basic Insulation Level:
a One Minute Power Frequency voltage :
1.16 Painting:
a. Enclosure Interior & Exterior :
b. Bus bar :
1.17 Minimum Clearance:
Page 1 of 42

CONTRACTOR
a. Phase to Phase :
b. Phase to Earth :
:
1.18 Applicable Standard
:
1.20 Span Between 2 support :
Page 2 of 42

CONTRACTOR
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. Inches
Isc = Short Circuit Symmetrical Fault Current in
=
KA
T = Fault duration in Sec =
T1 = Initial Temperature of Busbar in Deg.C =
T2 = Final Temperature in Deg.C =
A = Cross sectional area of busbar in Sq.inches =
A in sq.mm = A x 645.16
2.2 Required cross sectional Area
Actual Cross section of Bus bar Selected (As per

2.2 =
Clause1.13) in Sq.mm
Conclusion:
2.3 The required cross section 650.226 Sq.mm is less than actual cross section 1250 Sq.m
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 :
Open air rating of bus bar for 50 Deg. C rise over
:
ambient in Amps.
3.11
No. of times Interleaved (As per Clause1.11) :
Overall Rating of Bus Bar in Amps. :
3.12 Phase spacing in mm. :
3.13 Enclosed Size in (W x D x H ) mm :
3.14 Bus bar Enclosed in (W x D ) mm :
3.15 Design Ambient Temperature :
3.16 Maximum allowable temp. rise :
Page 3 of 42

CONTRACTOR
3.17 Enclosure Material :
Page 4 of 42

CONTRACTOR
3.18 De-rating / Up rating:
a Ambient correction factor for 35 Deg. Rise =
b Enclosure correction factor corresponding to bus bar =
c Enclosure Correction factor Material (MS) =

d Proximity Effect Factor =
e Bus bar Configuration Factor =
g Combined Correction Factor =
De-rated Current rating of bus bar after applying
3.19 =
Correction factor in Amps.
=
3.20 Rating of Panel required (As per Clause 1.5) =
Conclusion :
3.21 The de-rated Current rating 1238.51 amp of Panel selected is more than the required
amp of Bus duct Bus bar. Hence, the bus bar size chosen is safe for the envisaged sys
4 Support Insulator Span Calculation During Short Circuit
Fm = Peak Electromagnetic force along the centre
4.10 =
line of busbar without enclosure
a =
KA
b S = Phase spacing in Meter =
c K = Multiplying factor (s-a)/(a+b) =
corresponding to a that is 60 =
Fm (Nm / cm² ) =
Fm ( Kg / cm² ) = (Fm x 0.1019716) =
4.12 F = Force acting on top of the insulator =
a Where, H = Cantilever Height of insulator in mm =
h = Distance between surface of insulator to centre

b =
of Bus bar in mm
F =
Page 5 of 42

CONTRACTOR
4.13 Average span to be addopted in mm =
=
a SK = Cantilever strength of insulator(Kg/cm²) =
b SF = Safety factor =
Length of Span of insulator in mm =
Adopted Span is
Conclusion:
4.4 Average span of 586.278 mm is required but span adopted is 500 mm, hence it is safe
envisaged.
Page 6 of 42

CONTRACTOR
5 Temperature Rise Calculation
Where, I1=Calculated Rating in Amps (After
5.1 =
deration) As per Clause 3.19
5.2 I2 = Specified Rating in Amps as per clause 1.5 =
5.3 T1 = Max. Temp. Rise (in Deg.C) Specified =

5.4 T2 = Temp. Rise in Deg. C to be calculated as =
T2 =
=
Calculated Temperature is =
Conclusion :
5.5 The Calculated Temperature rise of bus bar is 24.64 Deg. C, which is within the desig
Deg. C and it is safe for the System envisaged.
Prepared By: Ganpat C Checked By : Kamlakar D. Approved B
Page 7 of 42
1000 A MCC BUSBAR SIZING CALCULATION
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
Cubical Type
3PH ,3 Wire / 4 Wire
415V
50 Hz.
1000
50
50
85
70
IP: 52 & IP: 42 for ACB Incomer
1 x 1 x 125 x 10 MM
1 x 125 x 06 MM
1
1
125
10
750
1250
SMC support with ribbed construction
2.5KV RMS
Epoxy paint RAL-7032, Siemens Grey

Heat Shrinkable Sleeved.
e:
Page 8 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
25 mm
20 mm
IS: 8623 Construction
IS : 5082 Bus bar
IP: 54 for Indoor & IP: 55 for Outdoor
0.5mtr. (500mm)
Page 9 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
alculation for MCC

l Withstand Capability of Bus bar
( Isc / √T ) / {14 x 10⁴ √log₁₀ [T1 +258)/
(T2+258)] }
50
1
85
200
1.0078517941
650.226
650.226 Sq.mm for pure aluminium.
1250
section 650.226 Sq.mm is less than actual cross section 1250 Sq.mm of the bus bar
e bus bar size chosen is safe for the envisaged system.
for Continuous Current Rating :
As per Clause1.11
1850
1 x 1850
1850
150
5500 x 800 x 2400 mm
800 x 400 mm
50 Deg. C
35 Deg. C
Page 10 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
MS Steel
Page 11 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
g:
0.9
0.87
0.9
0.95
1
0.67
1850 x 0.67
1238.51025
1000
nt rating 1238.51 amp of Panel selected is more than the required current rating 1000
us bar. Hence, the bus bar size chosen is safe for the envisaged system.
Span Calculation During Short Circuit
K x 16 x Isc² x 10⁻⁴ / S
50
0.250
0.904
0.4 (Reffering to curve K is 0.9)
14400.000
1468.391
Fm (H+h)/4H
38
75
1091.6328126316
Page 12 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
Cantilever Strength of insulator / safety factor x

F
Sk / (SF x F )
1600
2.5
586.278
OK
6.278 mm is required but span adopted is 500 mm, hence it is safe for the system
Page 13 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
Calculation
1238.51025
1000
35
( I1 / I2 ) = ( T1 / T2)0.61
T1 / (I1 / I2 )1.64
24.64
OK
mperature rise of bus bar is 24.64 Deg. C, which is within the design Specified Temp. 35
e for the System envisaged.
Checked By : Kamlakar D. Approved By : A.B.H
Page 14 of 42

CONTRACTOR
1 Input Data
1.1 Type of Panel :
1.2 System :
1.3 Rated Voltage :

1.6 :
for 1 Sec.)

No. of Runs :
1.11
1.16 Painting:
b. Bus bar :
Page 15 of 42

CONTRACTOR
a. Phase to Phase :
b. Phase to Earth :
:
:
Page 16 of 42

CONTRACTOR
=
Sq. Inches
=
KA
A in sq.mm = A x 645.16

2.2 =
Conclusion:
2.3 The required cross section 650.226 Sq.mm is less than actual cross section 900 Sq.mm
:
ambient in Amps.
3.11
Page 17 of 42

CONTRACTOR
Page 18 of 42

CONTRACTOR

3.19 =
=
Conclusion :
3.21 The de-rated Current rating 903.78 amp of Panel selected is more than the required c
of Bus duct Bus bar. Hence, the bus bar size chosen is safe for the envisaged system.
4.10 =
a =
KA
Fm (Nm / cm² ) =
Fm ( Kg / cm² ) = (Fm x 0.1019716) =

b =
of Bus bar in mm
F =
Page 19 of 42

CONTRACTOR
=
Adopted Span is
Conclusion:
envisaged.
Page 20 of 42

CONTRACTOR
5.1 =

T2 =
=
Conclusion :
Page 21 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
Cubical Type
415V
50 Hz.
630
50
50
85
70
1 x 1 x 75 x 12 MM
1 x 75 x 06 MM
1
1
75
12
450
900
2.5KV RMS

e:
Page 22 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
25 mm
20 mm
IS : 5082 Bus bar
0.5mtr. (500mm)
Page 23 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
alculation for MCC

( Isc / √T ) / {14 x 10⁴ √log₁₀ [T1 +258)/
(T2+258)] }
50
1
85
200
1.0078517941
650.226
900
As per Clause1.11
1350
1 x 1350
1350
150
7800 x 800 x 2400 mm
800 x 400 mm
50 Deg. C
35 Deg. C
Page 24 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
MS Steel
Page 25 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
g:
0.9
0.87
0.9
0.95
1
0.67
1350 x 0.67
903.77775
630
nt rating 903.78 amp of Panel selected is more than the required current rating 630 amp
r. Hence, the bus bar size chosen is safe for the envisaged system.
K x 16 x Isc² x 10⁻⁴ / S
50
0.250
0.904
14400.000
1468.391
Fm (H+h)/4H
38
75
1091.6328126316
Page 26 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4

F
Sk / (SF x F )
1600
2.5
586.278
OK
Page 27 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
Calculation
903.77775
630
35
( I1 / I2 ) = ( T1 / T2)0.61
T1 / (I1 / I2 )1.64
19.37
OK
Page 28 of 42

CONTRACTOR
1 Input Data
1.1 Type of Panel :
1.2 System :
1.3 Rated Voltage :

1.6 :
for 1 Sec.)

No. of Runs :
1.11
1.16 Painting:
b. Bus bar :
Page 29 of 42

CONTRACTOR
a. Phase to Phase :
b. Phase to Earth :
:
:
Page 30 of 42

CONTRACTOR
=
Sq. Inches
=
KA
A in sq.mm = A x 645.16

2.2 =
Conclusion:
2.3 The required cross section 650.226 Sq.mm is less than actual cross section 1000 Sq.m
:
ambient in Amps.
3.11
Page 31 of 42

CONTRACTOR
Page 32 of 42

CONTRACTOR

3.19 =
=
Conclusion :
3.21 The de-rated Current rating 1004.19 amp of Panel selected is more than the required
of Bus duct Bus bar. Hence, the bus bar size chosen is safe for the envisaged system.
4.10 =
a =
KA
Fm (Nm / cm² ) =
Fm ( Kg / cm² ) = (Fm x 0.1019716) =

b =
of Bus bar in mm
F =
Page 33 of 42

CONTRACTOR
=
Adopted Span is
Conclusion:
envisaged.
Page 34 of 42

CONTRACTOR
5.1 =

T2 =
=
Conclusion :
Page 35 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
Cubical Type
415V
50 Hz.
800
50
50
85
70
1 x 1 x 100 x 10 MM
1 x 100 x 06 MM
1
1
100
10
600
1000
2.5KV RMS

e:
Page 36 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
25 mm
20 mm
IS : 5082 Bus bar
0.5mtr. (500mm)
Page 37 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
alculation for MCC

( Isc / √T ) / {14 x 10⁴ √log₁₀ [T1 +258)/
(T2+258)] }
50
1
85
200
1.0078517941
650.226
1000
As per Clause1.11
1500
1 x 1500
1500
150
4400 x 800 x 2400 mm
800 x 400 mm
50 Deg. C
35 Deg. C
Page 38 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
MS Steel
Page 39 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
g:
0.9
0.87
0.9
0.95
1
0.67
1500 x 0.67
1004.1975
800
nt rating 1004.19 amp of Panel selected is more than the required current rating 800 amp
r. Hence, the bus bar size chosen is safe for the envisaged system.
K x 16 x Isc² x 10⁻⁴ / S
50
0.250
0.904
14400.000
1468.391
Fm (H+h)/4H
38
75
1091.6328126316
Page 40 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4

F
Sk / (SF x F )
1600
2.5
586.278
OK
Page 41 of 42
Revision : 01
Date : 24-05-2012
No. of Sheet - 4
Calculation
1004.1975
800
35
( I1 / I2 ) = ( T1 / T2)0.61
T1 / (I1 / I2 )1.64
24.11
OK
Page 42 of 42

MCC Bus Bar Sizing Calculation

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1000 A MCC BUSBAR SIZING CALCULATIO

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

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

Fault Current & Duration (KA RMS Symmetrical

1.7 Ambient Temperature (Deg. C.) :

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

2.2 Required cross sectional Area

Actual Cross section of Bus bar Selected (As per

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

3.17 Enclosure Material :

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

b Enclosure correction factor corresponding to bus bar =

c Enclosure Correction factor Material (MS) =

h = Distance between surface of insulator to centre

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

4.13 Average span to be addopted in mm =

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

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

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

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

Epoxy paint RAL-7032, Siemens Grey

alculation for MCC

650.226 Sq.mm for pure aluminium.

Cantilever Strength of insulator / safety factor x

Checked By : Kamlakar D. Approved By : A.B.H

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

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

Fault Current & Duration (KA RMS Symmetrical

1.7 Ambient Temperature (Deg. C.) :

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

2.2 Required cross sectional Area

Actual Cross section of Bus bar Selected (As per

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

3.17 Enclosure Material :

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

b Enclosure correction factor corresponding to bus bar =

c Enclosure Correction factor Material (MS) =

h = Distance between surface of insulator to centre

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

4.13 Average span to be addopted in mm =

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

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

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

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

Epoxy paint RAL-7032, Siemens Grey

alculation for MCC

650.226 Sq.mm for pure aluminium.

Cantilever Strength of insulator / safety factor x

Checked By : Kamlakar D. Approved By : A.B.H

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

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

Fault Current & Duration (KA RMS Symmetrical

1.7 Ambient Temperature (Deg. C.) :

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

2.2 Required cross sectional Area

Actual Cross section of Bus bar Selected (As per

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

3.17 Enclosure Material :

PROJECT 5000 TCD SUGAR PLANT WITH 30 MW POWER PLANT

b Enclosure correction factor corresponding to bus bar =