T

EN
SUBSTATION :‐

220/33kV SUBSTATION

M
TITLE:‐

BUSBAR DESIGN CALCULATION

U
C
O
D
E
PL
M
SA

1
PROJECT:220/33kV SS

BUSBAR DESIGN CALCULATION

1.0 SYSTEM DATA-220kV 220kV S/S Unit

1.1 Highest System Voltage V - 245 kV
1.2 Short circuit current Isc - 40000 Amps
1.3 Duration of Fault t - 1 sec
1.4 Factor of Peak short circuit current  - 1.81
1.5 System frequency f - 50 HZ

T
1.6 Design Ambient Temperature T - 50 0
C
1.7 a) Centre Line distance between conductors for
a - 4.5 m

EN
Strung bus
b) Centre Line distance between conductors for
a - 4 m
Equipment bus
(Refer.
1.8 Wind Pressure on conductor (Ref. Annexure-I) P - 148.002 Kg/m2
Annexure-1)
1.9 Maximum distance between two supporting

M
points for 4" EH IPS Al.Tube. L - 8.05 m

1.10 Line to ground distance of 4"EH IPS Al Tube. - 6 m

1.11 Line to ground distance of "TWIN MOOSE

U
ACSR". - 6/11.7/16.7/26.2 m

STRUNG BETWEEN
2.0 BUSBAR DATA:-

2.1 Busbar Used

C BUS

MOOSE
EQPTS
SCHEDULE
80
4" EH IPS
O
ACSR Al. Tube
2.2 Outer diameter Do - 31.77 114.3 mm
2.3 Inner diameter Di - ---- 97.18 mm
D

2.4 Area of Cross - section A - 528.5 2844 mm2

2.5 Moment of Inertia J - ---- 399.998 cm4
2.6 Weight per unit length of conductor m' - 1.999 7.678 Kg/m
2.7 Section modulus Z - ---- 69.989 cm3
E

2.8 Young's modulus E - 6.9000E+10 6.5727E+10 N/m2

2.9 Yield point Rp0.2 - ---- 161.865 N/mm2
2.10 Ultimate Bending stress of Al.Alloy
PL

- ---- 201.105 N/mm2

2.11 Intial temp.of busbar before short circuit I - 75 85 o
C
2.12 Final temp.of busbar before short circuit F - 200 200
o
C

3.0 REFERENCES:-
M

1 IEC 865 - Short circuit currents - Calculation of effects.

2 IEC 909 - Short circuit current calculations in three phase AC systems
3
SA

Indal Aluminium busbars book.

4 IS:802-Code of practice for Use of structural steel inoverhead transmission line towers.
5 Electra-68-1980

2
BUSBAR DESIGN CALCULATION
PROJECT:220/33kV SS

CALCULATION FOR 220kV S/S:-

CHECK FOR MAX. CONTINUOUS CURRENT CARRYING CAPACITY

1.0
OF ' MOOSE ' ACSR CONDUCTOR:
TWIN Moose ACSR for Main Bus I &
Conductor used =
Main Bus II
Continuous current rating of " Single Moose ACSR " at (As per diamond cables
= 836 Amps
75°C catalogue page no:79)
Hence current carrying capacity of "TWIN MOOSE
= 1672 Amps
ACSR"

Full load current on the 220kV side of 10MVA Trf.(3ϕ) = ₃

10 x10⁶/(√3 x220 x 10 )

= 26.2 Amps

T
Total current on Main bus,Considering 2 Nos of 3ϕ
= 2X26.2
Transformers.

EN
= 52.5 Amps
Hence "TWIN MOOSE ACSR" for main bus is adequate

2.0 CHECK FOR SHORT TIME RATING OF MOOSE ACSR:

1) Conductor Temperature at the beginning of a short circuit θb = 75oC
2) Conductor Temperature at the end of a short circuit θe = 200oC ( As per table 6 of IEC‐865‐1)

M
2 ( As per Fig 13 of IEC‐
3) Rated short time withstand current density for 1sec. Sth = 82 Amp/mm
865‐1)
4) Hence short time withstand rating of MOOSE ACSR = 82 x 528.5
= 43337 Amps
5) Short Circuit Rating of 220KV System = 40000 Amps

U
HENCE SAFE

3.0 CHECK FOR SHORT TIME RATING OF AL.TUBE:

Required area of cross-section of AL.Tube(A)

A =
C
Isc xt

2.17 x 104 x Log{0F + 258/01 +258}

As per INDAL AL. busbar Book.
O
Where
A - Required area of Aluminium conductor in cm 2
Isc - Symmetrical short circuit currents in Amps
t - Duration of fault in seconds
D

0l - Initial temperature before short circuit in °C

0F - Final temperature after short circuit in °C

40000 x √1
A =
E

2.17 x10000 x Log{(200+258)/(85+258)}

A = 5.2018 cm2
A = 520.18 mm2
PL

Area of cross - section of selected busbar.

2
a) 4" IPS AL.Tube (SCH.80) = 2844 mm
HENCE SAFE

4.0 CHECK FOR CONTINUOUS CURRENT RATING OF AL. TUBE:

M

Busbar used = 4" EH IPS Al. Tube (SCH.80)

Current carrying capasity of 4" EH IPS
(As per INDAL AL.
Al. Tube for Temp. rise of 50 Deg.C over an ambient of 35 = 3590 Amps
busbar Book.)
Deg.C
Correction Factor for temp. raise of 35 Deg.C over an
SA

= 0.815 (As per Table 5 of INDAL AL BUSBAR BOOK)

ambient of 50 Dec.C
Continuous current rating of Al. Tube for
35 Deg.C temperature rise over 50 Deg.C = 3590 x 0.815
Ambient.
= 2925.85 Amps
Max. Bus Bar Rating = 1600 Amps

Hence 4" EH IPS Al.Tube is adequate.

3
BUSBAR DESIGN CALCULATION
PROJECT:220/33kV SS

5.0 CHECK FOR VOLTAGE GRADIENT:-

5.1 Average voltage gradient at the surface of the bundled conductors

V
kV/cm
Ea = n x r x ln (2 x he / re)

Where,
re = r x [ k x s / r]n-1/n cm

he = hxd
cm
[(2h)2 + d2]

Where,
V - Highest line to ground voltage in kV
- 141.5 kV
n - No.of conductors in the bundles

T
2 for twin conductors
1 for Single conductors
r - radius of the individual conductor in cm

EN
- 3.177/ 2 = 1.5885 cm ( Moose ACSR)

- 11.43/2 = 5.715 cm (4" EH IPS Al.Tube)

k - constant
- 1 for Single & twin conductors
s -
Sub conductor spacing in the bundle in cm
- 25 cm
h -
Line to ground distance in cm.

M
- 600 cm For Equipment Bus
- 1170 cm For Main Bus
- 1670 cm For Main Bus
- 2620 cm For Jack Bus
d -
Phase to phase spacing in cm.

U
- 400 cm For Equipment Bus
- 450 cm For Strung bus
re -
Eqivalent single conductors of bundled conductors in cm
he -
Eqivalent single phase line to ground distance of a
three phase system in cm
5.2 Equivalent single conductors of bundled conductors(re)

ForTwin Moose ACSR(Main Bus) conductor

C
O
re = 1.5885 x [1 x 25] [2 - 1 ] /2
1.5885

= 6.3 cm
D
5.3 Eqivalent single phase line to ground distance of a three phase system (he)
a) For 4"EH IPS Al.tube bus at 6.00 m level

600 x 400
he =
[(2 x 600) x (2 x 600)] + [400 x 400]
E

= 189.74 cm
b) For TWIN MOOSE ACSR at 6.0 m level
PL

600 x 400
he =
[(2 x 600) x (2 x 600)] + [400 x 400]
= 189.74 cm

c) For TWIN MOOSE ACSR at 11.7 m level

M

1170 x 450
he =
[(2 x 1170) x (2 x 1170)] + [450 x 450]
= 220.95 cm
SA

d) For TWIN MOOSE ACSR at 16.7 m level

1670 x 450
he =
[(2 x 1670) x (2 x 1670)] + [450 x 450]
= 222.99 cm

e) For TWIN MOOSE ACSR at 26.2 m level

2620 x 450
he =
[(2 x 2620) x (2 x 2620)] + [450 x 450]
= 224.17 cm

4
BUSBAR DESIGN CALCULATION
PROJECT:220/33kV SS

5.4 Average voltage gradient at the surface of the bundled conductors (Ea) / 4"EH IPS Al.Tube :

a) For 4"EH IPS Al tube at 6.00 m level

141.5
Ea =
1 x 5.715x ln 2 x189.74 kV/cm
5.715

= 5.9 kV/cm

b) For TWIN Moose ACSR conductor at 6.0 m level

141.5
Ea =
2 x1.5885x ln 2 x189.74 kV/cm
6.3

T
= 10.87 kV/cm

c) For TWIN Moose ACSR conductor at 11.7 m level

EN
141.5
Ea =
2 x1.5885x ln 2 x220.95 kV/cm
6.3

= 10.48 kV/cm

d) For TWIN Moose ACSR conductor at 16.7 m level

M
141.5
Ea =
2 x1.5885x ln 2 x222.99 kV/cm
6.3

= 10.46 kV/cm

U
e) For TWIN Moose ACSR conductor at 26.2 m level

141.5
Ea =
2 x1.5885 x ln 2 x224.17 kV/cm

= 10.44 kV/cm
6.3
C
O
Allowable voltage gradient at the surface of the conductor is
20kV/cm.
HENCE SAFE
D
5.5 Average voltage gradient at the surface of the Single conductors

V
Ea = kV/cm
r x ln (2 x h / r)

Where,
E

V - Highest line to ground voltage in kV

- 141.5 kV
r - Radius of conductor in cm.
- 1.5885 cm
PL

h - Line to ground distance in cm.

- 2620 cm (For Strung bus)
- 600 cm (For Equipment bus)

a) For Single Moose ACSR conductor at 26.2 m level

141.5
Ea =
M

1.5885 x ln 2 x2620 kV/cm

1.5885

= 11 kV/cm

b) For Single Moose ACSR conductor at 6.0 m level

SA

141.5
Ea =
1.5885 x ln 2 x600 kV/cm
1.5885

= 13 kV/cm
Allowable voltage gradient at the surface of the conductor is
20kV/cm.
HENCE SAFE

5
BUSBAR DESIGN CALCULATION
PROJECT:220/33kV SS

6.0 CALCULATION FOR FIBRE STRESSES ON TUBULAR BUSBAR(4" EH IPS .SCH:80):-

6.1 CALCULATION FOR MAXIMUM SPAN WITH ONE END RIGID AND OTHER END
SIMPLY SUPPORTED

6.1.1 Maximum force acting on the central conductor during 3 phase

short circuit (Fm3) is

Fm3 = 0.2 x 0.87 x i2p3 x L

N
a
Where
i2p3 = Peak short circuit current in kA
Isc x 1.81 x 2
=
1000

T
= 102.0 kA
Therefore,
0.2 x 0.87 x102 x 102 x 8.05

EN
Fm3 = N
4
= 3643 N

6.1.2 Natural frequency of the tubular busbar of a single conductor

 ExJ
fc = x HZ
L2 m'

M
Where
 - Factor of natural frequency estimation
= 2.45 (From table -III of IEC 865-1)
 - Factor for main conductor stress

U
= 0.73 (From table -II of IEC 865-1)
E - Young's modulus of Al.tube in N/m 2
2
= 65727000000 N/m
Moment of Inertia in m 4
J

m'
-
=
-
=
0.00000399998 M4
mass per unit length of conductor in Kg/m
7.678 Kg/m
C
O
L - Distance between two supporting points of Al. Tube
= 8.050 m
Therefore,

fc 2.45 ( 65727 x 106 ) x ( 399.998 x 10-8 )

D
= x
8.05 x 8.05 7.678

= 7.00 Hz

6.1.3 Ratio fc/f :

E

7
fc / f =
50
= 0.14
PL

From the fc/f value, the factors V and Vr are calculated as follows:
a) Ratio of dynamic and static main conductor stress
Refer page no 109 of IEC-865-1
for 0.04< fc/f < 0.8

V = 1
M

-1.68
V = 0.756 + 4.49 e + 0.54 log (fc/f)

Where
 = 1.6 for >1.6
SA

-1.68
V = 0.756 + 4.49 e + 0.54 log (fc/f)

= 0.756 + 4.49 x Exp - (1.68 x1.6 ) + 0.54 log (0.14)

= 0.600

V = 1.0
Therefore,
V = 0.600
b) Ratio of stress for main conductor with three phase auto-reclosing (Vr):-
Refer page no 109 of IEC-865-1
for 0.05 < fc/f < 1.0

Vr = 1.0 - 0.615 log (fc/f )

= 1.0 - 0.615 log (0.14 )

= 1.525

6
BUSBAR DESIGN CALCULATION