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
