Example:
Design a three phase rigid bus with the following characteristics:
Total bus length : 45.72m, assuming four equal spans of 11.43m
Voltage : 161kV
BIL : 750kV
Insulator Type : post
Continous current rating : 1800A
Short circuit current : 24kA rms symmetrical
Altitute : 304.8m
NESC : Heavy
Disconnect switch connected to one end of bus
External prefabricated dampers to control condutor vibration
Horizontal Wind Pressure : 191.5Pa
Assuming a total conductor temperature variation of 50oC
Solution:
a) Material and size selection:
Refer to Table 2.11: Schedule 40 6063-T6 Aluminium alloy
For Continuous current rating = 1890A, size conductor = 3 in x 2.54cm = 7.62cm
Weight, Wc = 38.249Nm (Table 2.12)
Outside diameter, d2 = 3.500 in x 2.54cm = 8.890cm (Table 2.12 or Table 2.11)
Moment of inertia, I = 125.577cm4 = 125.6 cm4 (Table 2.12)
Modulus of elasticity, E = 6.9 x 107 kPa (Google: Aluminium 6063 T6 = 68.9GPa)
Section modulus, S = 28.251cm3 (Table 2.12)
Maximum allowable fiber stress, FB for 6063-T6 Aluminium Alloy = 1.38 x 105kPa
Note: If damping cables are to be used to control conductor vibration, the cable weight has to be
added to conductor weight. In this example, external prefabricated dampers will be used for
vibration control.
Table 2.11: Current Ratings for Bare Aluminium Tubular Bus, Outdoors
(Ratings based on 30oCover 40oC ambient, 98% conductivity copper, frequency 60Hz, wind
velocity 2ft/s at angle 90o angle)
Nominal size Outside Inside Current ratings, A
diameter, in diameter, in 6063-T6 6061-T6
ASA Schedule 40 (standard pipe size)
½ 0.840 0.622 405 355
¾ 1.050 0.824 495 440
1 1.315 1.049 650 575
1 1/4 1.660 1.380 810 720
1 1/2 1.990 1.610 925 820
2 2.375 2.067 1150 1020
2 1/2 2.875 2.469 1550 1370
3 3.500 3.068 1890 1670
3 1/2 4.000 3.548 2170 1920
4 4.500 4.026 2460 2180
5 5.563 5.047 3080 2730
ASA Schedule 80 (extra heavy pipe size)
½ 0.840 0.546 455 400
¾ 1.050 0.742 565 500
1 1.315 0.957 740 655
1 1/4 1.660 1.278 930 825
1 1/2 1.990 1.500 1070 945
2 2.375 1.939 1350 1200
2 1/2 2.875 2.323 1780 1580
3 3.500 2.900 2190 1940
3 1/2 4.000 3.364 2530 2240
4 4.500 3.826 2880 2560
5 5.563 4.813 3640 3230
6063-T6 = 53% IACS typical
6061-T6 = 40% IACS typical
Note: 1 in = 25.4mm
Source: Data from Aluminium Company of America
Table 2.12: ASA Schedule 40 Aluminium Pipe Conductors Physicals Properties, Hubbell
Technical Data, Table 52.
b) Spacing:
Refer to Table 2.5, Bus centerline to centerline spacing, D = 274cm
Table 2.5: Outdoor Electrical Substation Clearances
c) Short circuit current forces:
Ksc = 0.67
i = 24 kA
5 i2
FSC 13.9 x10 K SC
D
24000 2
(13.9 x10 5 )(0.67 )( ) 195 .8 N / m
274
d) Loading:
From Table 2.13, Radial thickness of ice, dice = 1.27cm
Horizontal wind pressure, PW = 191.5Pa
Ice loading:
WI 0.704 (d12 d 22 )
Refer to Table 2.12, Outside diameter of Schedule 40 6063-T6 Aluminium alloy ,d2 = 8.890cm
Where
d1 = d2 + 2(Radial thickness of ice)
= 8.890 + 2(1.27)
=11.43cm
Therefore
Ice loading, WI 0.704 (11.43 2 8.890 2 ) 36.3N / m
The Wind loading, FW 0.01PW d1 0.01(191 .5)(11.43) 21.9 N / m
The total bus conductor loading:
FT ( Fsc FW ) 2 (WC WI ) 2
(195 .8 21.9) 2 (38.2 36.3) 2 230 .1N / m
e) Support spacing:
FB S
The maximum bus support spacing, LM K SM
FT
Four equal spans of 11.43m (L) were assumed. From Table 2.7, Ksm = 0.096 for three or more
equal spans.
Table 2.7: Conductor Maximum Span and Deflection Multiplying Factors
Bus System KSM KSE KDM KDE
Conductor fixed both ends 0.110 1.0 2.6 x 104 4.5
Conductor fixed one end, 0.090 0.82 5.4 x 104 9.34
simply supported other end
(single span)
Conductor simply supported 0.090 0.82 1.3 x 105 22.5
(single span)
Conductor simply supported 0.090 0.82 5.4 x 104 9.34
(two equal spans)
Conductor simply supported 0.096 0.88 6.9 x 104 11.9
(three or more equal spans)
6063-T6 aluminum alloy,
FB = 1.38 x 105 kPa
Section modulus, S = 28.251cm3 (Table 2.12)
(1.38 x10 5 x 28.2)
The maximum bus support spacing, LM (0.096 ) 12.48m
230 .1
The assumed spacing of 11.43m is structurally permissible for the conductors.
f) Deflection:
Maximum vertical conductor deflection:
(WC WI ) L4
y K DM
EI
Four equal spans of 11.43 meters were assumed. From Table 2.7, KDM = 6.9x104 for three or
more equal spans.
(38.2 36.3)(11.43) 4
y cal (6.9 x10 4 ) 10.1cm
(6.9 x10 7 )(125 .6)
Maximum permissible deflection is
(11.43m)(100 )
y max 5.72cm
200
Since the calculated deflection is greater than the maximum permissible deflection, the design
has to be modified. The span length will be reduced to five equal spans of 9.14m (45.72m /5)
each. The maximum vertical deflection is then recalculated:
(38.2 36.3)(9.14) 4
y recal (6.9 x10 4 ) 4.14cm
(6.9 x10 7 )(125 .6)
Maximum permissible deflection is
(9.14 m)(100 )
y max 4.57 cm
200
Since the calculated value with 9.14m (LNew) support spacing is less than the maximum
permissible deflection, this support spacing is adequate.
g) Cantilever Strength:
The minimum required support insulator cantilever strength
WS 2.5( FSC FW ) Ls
9.14 9.14
(2.5)(195 .8 21.9)( ) 4974 N
2 2
From Table 2.14, select Technical Reference Number 291 for 5338 N cantilever strength post
type insulators.
Table 2.14: Typical Characteristic of Post Type Insulators
h) Thermal Expansion: Provide for conductor expansion:-
Assuming a total conductor temperature variation of 50oC, the total conductor expansion is:
T
(2.3x10 5 )(45.72)(100 )(50) 5.26cm
Some means has to be provided to account for this change. Figure below illustrates one method
that can be used that permits free expansion in all spans.
Figure :Coupler Location
i) Couplers: Locate conductor couplers:-
From Table 2.10, the ideal coupler locations for the span bus of 9.14m spans measure to the right
from the left most support are follows:
1 7.2m
2 11.6m
3 16.3m
4 20.1m
5 25.6m
6 29.4m
7 34.1m
8 38.5m
Table 2.10: Ideal locations for couplers in continuous uniformly loaded rigid conductor
These locations are illustrated in Figure 2. Assuming that the bus conductor is available in
12.19m lengths (Industrial Standard: 3 to 12m, Longer lengths are available in various sizes), the
coupler should be positioned at points 2, 4, 6, and 8. The conductor lengths are cut as required to
position the couplers at these approximate locations..
Figure 2: Bus Configuration
Legend:
SF = Slip fit for support
F = Fixed bus support
EX = Expansion terminal