BUSBAR SYSTEMS - An Introduction
                                                                     

          Throughout my nearly five decades of experience in the manufacture of electrical engineering products, I've observed a notable gap in the available literature: no single book consolidates all the essential information on Busbar Systems. These systems play a crucial role in both AC and DC power distribution, with applications ranging from low voltage, under 1 kV, to ultra-high voltage, up to 1200 kV, in switchyards and transmission lines. The rated current can range from a few tens of amperes in small-scale distributions to 600 kA in large industrial plants like Aluminium extraction facilities. Unfortunately, most information is scattered across books, technical journals, manufacturers’ catalogues, and manuals, with many industrial practices kept out of the public domain. This book aims to bridge that gap by providing comprehensive guidance on various aspects of Busbar Systems.

          Busbar Systems are inherently project-specific, requiring careful engineering for component selection, sizing for ambient and service conditions, and layout design. Due to their complex nature, not all solutions can be documented in a design guide. A design engineer must rely on years of experience, often drawing from similar projects and feedback from manufacturing and installation to arrive at an optimal solution quickly. Every project presents unique challenges, and yet, once executed, the simplicity of the product belies the effort and expertise involved, often leaving its importance underappreciated.

          Installation is another critical factor in the performance of a Busbar System. The system is only as effective as its installation, necessitating skilled personnel with specialized knowledge. Even well-manufactured products can fail due to poor installation.

          I have noticed that the specifications for procuring Busbar Systems are often drafted by individuals with limited expertise. Standardized specifications are used without considering the specific requirements of the project. Moreover, unnecessary stringent requirements are added, mistakenly believed to enhance safety margins. These additions only increase costs without improving performance, reliability, or longevity.

          Busbar Systems are defined by different voltages, currents, and insulating materials, and therefore, they are governed by various standards. Most countries follow national standards aligned with either the American National Standards Institute/Institute of Electrical & Electronics Engineers (ANSI/IEEE) Standards or the International Electrotechnical Commission (IEC) recommendations. Differences in definitions, testing procedures, preferred values, and acceptance norms between ANSI/IEEE and IEC make the specification and testing of Busbar Systems even more challenging.

This book is intended for a diverse audience, including:

• Project authorities, for conceptualizing and selecting the most suitable Bus Product
• Consultants, for drafting specifications
• Procurement staff, for techno-commercial evaluations
• Design engineers, for finding optimal solutions
• Manufacturers, for understanding materials, components, and processes
• Vendors, for grasping bus component applications
• Testing engineers, for identifying key parameters
• Installers, for understanding sequence and critical aspects
• Maintenance staff, for familiarizing with the product
• Inspectors, for conducting Failure and Root Cause Analysis

          An effort has been made to consolidate all aspects of Busbar Systems into a single resource. The book provides an introduction to various types of Busbar Systems, catering to professionals from different backgrounds. The theoretical content has been kept minimal, with references limited to a few classic papers.

The book consists of 18 chapters, broadly classified as follows:

• Three chapters covering conductors, enclosures, and insulating materials
• One chapter on key industry processes
• Three chapters on impedance, ampacity, and short circuit forces
• Nine chapters on different types of Busbar Systems
• Two chapters on Busduct and generator connection accessories

          Detailed discussions are provided on Isolated Phase Bus, Non-Segregated Phase Bus, Segregated Phase Bus, Sandwich Bus, and Gas Insulated Bus, as they form the core of bus connections and are project-specific.

          All current-carrying conductors generate losses, and in today’s climate-conscious world, it is crucial to factor these into life cycle costing. This involves amortizing running costs based on expected lifespan, energy tariffs, and interest rates. However, while these parameters can be assigned values for a relative evaluation, exact life cycle costs are more challenging to assess, and project risk remains difficult to quantify. This book does not delve into life cycle costing.

          The book is structured to be read sequentially, from the first to the last chapter.

          I encourage practicing engineers to familiarize themselves with the definitions and intents behind each statement in ANSI/IEEE Standards, IEC recommendations, and their associated specifications relevant to Busbar Systems.

          Finally, I must acknowledge that my contribution to this book lies primarily in organizing and presenting information in a coherent and readable format. The content is largely drawn from manufacturers’ catalogues, descriptive literature, journals, and technical papers available in the public domain.

          I welcome any suggestions for improving the scope and quality of this book.

I intend to post contents from the book elaborating on theory and industrial practices.

V. Balachandran

bala@busbarsystems.net