STUDY OF SANDWICH BUSDUCTS AND THEIR USAGE IN

NAVEL JETTIES (VISAKHAPATNAM)

Nitin Sharma, IDSE
Garrison Engineer (Services) Vizag, DGNP(V)
Email: nitin1990ee@gmail.com

ABSTRACT
This paper talks about how Sandwich Busducts are being suitably considered for the
transmission of electric power from the utility building to the Navel Jetty cope points and
various aspects about the Sandwich Busducts which can be very widely used in Military
Engineer Services (MES).

INTRODUCTION
There are many work projects for the construction/augmentation of Navel Jetties at
Visakhapatnam under DGNP(V). These projects are at various stages of planning and
execution. Some of these projects are at east side channel jetties as well, where, as an
extension of the existing jetties of vintage 1980s, the new jetties are being constructed
(towards sea side) whose all the utility services (electric supply, fresh water supply,
firefighting, chilled water supply, HP/LP air supply etc.) are also being provisioned by
DGNP(V). There is a running project of “construction of special jetty with covered
shed(phase-2)” and another project of “Augmentation of utilities and services interconnection
at 150m Gap Jetty” which is under planning stage. To feed the various utility services for
both of these jetties, a common utility building at distant location, on the other side of the
existing jetties has been planned, which contains all the utility equipments including various
HT and LT electrical equipments.

CHALLENGES
While planning these services schemes, one of the major challenges was to plan the electric
supply services for the upcoming jetties. The submarines and ships have the huge
requirements of electricity which is to be fulfilled by placing the electrical cope points of
various ratings at strategic distributed locations on the jetty. But at the same time while
planning the schemes the first and foremost point to keep in the mind is saving of jetty space
by not placing/installing any electrical equipment on navel jetties other than electrical cope
points. The electrical load requirements at the cope points are very high and specific for
example: 3500A/2500A/2000A/1600A/800A/630A/250A at 415V or 2500A/250A at 380V.
Two of the adjacent jetties on east side channel planned to have one common utility building
but a total of 16 cope points to be installed at distributed strategic locations across the total
jetties’ length of about 330m (180m special jetty with covered shed+150m gap jetty). Further
the transmission of electricity can only be carried out through the very limited space available
inside the old existing service galleries (4 numbers) under the vintage jetty existing between
the utility building and the new upcoming jetties (having 2 numbers of service galleries).
Therefore, the meticulous planning of these services was a highly challenging task.
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METHODOLOGY
Conventionally to feed the larger electrical loads, a number of power cables running parallel
to share the load are used. For example: to feed a load of 2000A at a given cope point, about
5 runs of 500 sqmm 3.5 core XLPE LT Cable are suitably used, or for a given load
requirement of 4000A, about 9 runs of 500 sqmm 3.5 core XLPE LT Cable are suitably used.
But by using this methodology there would have been around 40-50 runs of LT Cables
required to feed 16 number of cope points located at various locations throughout the two
adjacent jetties having a span of about 330 running meters. Handling, maintaining and fault
identification in such a large number of power cables is very cumbersome task. Further the
problem of voltage drop, continuous energy losses, damage by rodents and in case of fire
there would have been a fire hazard for all the adjacent cables within the service galleries.

Hence, it was decided that a total of six number of busducts will run originating from LT
panels (next to six number of transformers) installed in the utility building and terminating to
the 8 number of cope points of first jetty (special jetty with covered shed jetty) in the first
phase and in the second phase these electrical supply services will be extended for the
balance 8 number of cope points of second jetty (150m gap jetty). For this, the busducts are
planned to be extended by putting the T-joints at the point of extension(notch). Also, the size
of busduct get decreases after every tapping point as the busducts travels to the farther
distances, in an analogous fashion of water supply pipelines or air handling ducts.
As compared to power cables, this arrangement of busducts is not only safer and more secure
but also relatively easy to install and of superior aesthetical appearance. In order to have
lesser losses and enhanced reliability in the distribution system, busducts are preferred over
cables for higher current ratings and shorter lengths at different voltage levels.

ABOUT BUSDUCTS
Definition: Busduct is a sheet metal duct with aluminium or copper busbars, and used as a
reliable link for transferring power from one equipment to other at desired voltage levels. The
busbars are enclosed by suitable enclosures to prevent the busducts from getting damaged
from foreign bodies. It is used as an alternate means to power cables for conducting the
electricity.
There are mainly two types of busduct systems based on the type of construction: Air-
insulated busduct and Sandwich busduct. An air-insulated busduct construction has air as
an insulating medium between conductors, hence the overall size of this type of busduct
is greater compared to a sandwich busduct. Whereas, Sandwich construction means that
the conductors are individually insulated and mounted so as to resemble a sandwich of
conductors and insulation (like Mylar film), within the busduct casing.

Applications: Sandwich busducts finds application in power transfer and distribution

solutions replacing cables between:
 Transformer to Switchgear Panels
 Interconnection between Switchgear Panels
 Diesel Generator to Synchronizing/ Switchgear Panels
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  Rising mains or Vertical distribution
 Horizontal distribution

Above Applications will find Transmission and Distribution solutions in following segments:
 Process plants, Manufacturing Industries and Industrial Offices
 Commercial, Residential real estate, Schools and Hospitals
 Infrastructure establishment – Airports, Metros, Railways, Ports
 Shopping Centres, Exhibition Centres & Warehouses,
 IT Parks, Data centres solutions, Solar farms.

Many people believe busducts only serve high amperage applications. This is a
misconception, busduct can provide a high degree of efficiency for both low and high
amperage situations. Busducts are manufactured typically ranging from 100A to 6500A.
Some low amperage applications could be server room, technical area etc. High amperage
busduct systems could be heavy assembly industries like manufacturing units, auditoriums,
repair workshops and navel jetties.

Advantages:
Space Saving: Due to the compact design of busduct, it requires lesser space than traditional
cabling system and this is a major advantage when thousands of amperes of electricity need
to be transmitted.
Less Voltage drop: Busducts have rigid design elements and hence have better resistance
than cables, especially in case of short circuits. Busducts also have a thin and flat tire which
helps in optimal distribution of current density and in turn reduces the resistance. Also due to
minimum distance between the conductors, inductive reactance also reduces. Therefore, the
overall impedance per unit length is lower than cables. This gives less voltage drop and
superior voltage regulation.
Greater Efficiency: Since the busducts have lower resistance than cables, hence for any
given current supply, lesser energy(variable) losses are there, which results in higher
efficiency.
Lower Electromagnetic Field: Due to compact design and metal shell, a comparatively lower
electromagnetic field is created around a busduct as compared to a cable. Therefore, resulting
into very less radio interference with communication and data cables.
Safe and Secure: Busducts have sturdy and robust metal enclosure which gives it high
mechanical strength and cannot be damaged by rodents as comparable to power cables. They
have higher short circuit withstand capacity as compared to the cables.
Heat Absorption: Since the design is compact and have a metal casing with well-defined
surface, busducts can absorb heat generated during transmission and distribution of electricity
in the walls of the enclosure. Their system of cooling is much better than traditional cabling
system.
Length Independency: In case of traditional cables connecting a phase with high amperage,
the length of the cables varies both on location and connection. But in case of busducts, the
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difference of length is eliminated since they have the parameters of active and inductive
reactance to ensure that the load on each phase is equal.
Flexibility: Busducts are more flexible in nature as compared to cables in the sense that it can
be used in any kind of structure with any configuration. Thanks to developments like elbows
and offsets, bus duct offers a lot of layout flexibility, like adapting to directional changes.
They are easily modifiable, reusable, upgradable and also can be relocated without much
capital expenditure. Any section of busduct system can be removed without disturbing
the adjacent sections. Plug-in and Tap-off units or new sections can easily help meet load
changes at any stage.
Ease of Installation: Busducts require lesser installation time, lesser manpower requirement
for installation and lesser installation cost as compared to power cables.
Aesthetical Appearance: The system is simple, compact and adds a touch of elegance to
the ambience after installation.
Ease of Distribution: Busducts help in easy, efficient and safe distribution of power with the
junction boxes in places where they are required. Moreover, their location can be changed
whenever and where-ever in future. In a cable system, if the load on any section exceeds
the limits, an additional cable has to be run from a spare feeder on the main board to
that section, whereas in a busduct system, each plug-in box can normally be added to or
removed with the busduct in live condition, eliminating production downtime.
Standard cells: Fully certified standard cells like junction boxes and plugs are being offered
by their manufacturers, which are an integral part of busbars which is meant to eliminate
human error. Therefore, busducts offers convenience with better safety factor.

Parts of Busduct System:

Typically, a busduct system will consist of straight lengths, joints, flanged ends, elbows,
end feed boxes, end covers, reducers, plug-in boxes and other accessories.

Fig: Straight Length (Feeder) Fig: Uniblock Joint

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 Fig: Edge Elbow Fig: Flat Tee Joint

Fig: Flanged Ends Fig: End Cover

Fig: End Feed Direct Fig: Centre Feed Direct

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 Fig: Reducer (Direct) Fig: Section Isolator

Fig: Plug in box

Typical Standard-Ratings of a Sandwich Busduct System:

Applicable Standard IEC 61439

Busduct Sandwich Type

Construction
Aluminium - 250A to 5000A Copper -
Busduct Rating
400A to 6300A
Rated Operational 415V / 690V and maximum up to 1100V
Voltage

Rated Insulation 1100V

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 Voltage
Rated Impulse 8kV / 12kV (1.2/50 µs)
Voltage
Rated Dielectric
Voltage 2.5kV for 5 sec

Rated Frequency 50Hz / 60Hz or DC operations

Degree of Protection IP54 / IP55 for Indoor and IP65 / IP66 for Outdoor and IP68 on
request

Insulation Class Class-F (155 degree C)

Insulation Material Multilayer Polyethylene Terephthalate

Enclosure Material Aluminium Busduct - 1.6mm GI or 2.5mm Alloy

Copper Busduct - 2.5mm Alloy
Surface Coating on Epoxy Powder Coating
Enclosure

Plug-in Box 16A to 630A

Tap-off Box 100A to 1250A

Joint Block Uniblock joint with twin-headed maintenance-free nut

Seismic Compliance Seismic Zone 5 compliance, as per IS 1893 (Part 1) - 2002 and
IEEE 693 – 2005 Tested with Vertical+Horizontal busduct and
Plug-in Box assembly
Fire Resistance rating Verified for Integrity: 240 minutes (ISO 834)
in Building
Penetration

Resistance to Flame Verified

Propagation

 3 Phase + Integral Ground Earth or

Busduct Configuration  3 Phase + 100% Neutral+ Integral Ground Earth or
 3 Phase + 100% Neutral+ 50% Internal Earth +Integral
Ground Earth or
 3 Phase + 100% Neutral+100% Internal Earth+ Integral
Ground Earth or
 3 Phase + 200% Neutral+ Integral Ground Earth

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Typical Dimensions Available (Aluminium Busduct):

Dimensions (mm) Weight (Kg/m) *

Current Rating (A) Busduct configuration
Conductor Size Height (H) Width (W)
3W 4W 5W
250A 1-6X30 135 70 7 7 8
400A 1-6X40 135 80 8 9 9
630A 1-6X60 135 100 10 11 12
800A 1-6X80 135 120 11 13 14
1000A 1-6X100 135 140 13 15 16
1250A 1-6X125 135 165 15 17 19
1600A 1-6X150 135 190 17 19 22
2000A 1-6X200 135 240 21 25 28
2500A 1-6X250 135 290 25 29 33
3200A 2-6X150 135 380 34 39 44
4000A 2-6X200 135 480 42 49 55
5000A 3-6X200 135 720 64 73 83
*Weight given in above table is straight feeder weight; it can vary by +/-5%

Typical Dimensions Available (Copper Busduct):

Dimensions (mm) Weight (Kg/m) *

Current Rating (A) Busduct configuration
Conductor Size Height (H) Width (W)
3W 4W 5W
400A 1-4X40 135 78 8 10 11
630A 1-6X40 135 78 10 12 14
800A 1-6X50 135 88 12 15 18
1000A 1-6X55 135 93 13 16 19
1250A 1-6X75 135 113 17 21 25
1600A 1-6X102 135 140 23 28 33
2000A 1-6X140 135 178 30 37 45
2500A 1-6X175 135 213 37 46 55
3200A 2-6X102 135 280 49 56 70
4000A 2-6X140 135 356 60 75 89
5000A 2-6X175 135 426 74 92 111
6300A 3-6X160 135 594 102 127 152
*Weight given in above table is straight feeder weight; it can vary by +/-5%

Short Circuit Withstand Capacity:

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 Short Circuit Rating (kA for 1 Sec)
Current Rating
(A) Aluminium Copper
250A 18 -
400A 25 25
630A 40 40
800A 50 50
1000A 50 50
1250A 65 65
1600A 80 80
2000A 80 80
2500A 80 100
3200A 100 100
4000A 100 100
5000A 100 100
6300A - 100

Care and Maintenance:

 Inspect the busduct once in six months or after any severe electrical short circuit or ground
fault.
 Perform an infra-red temperature scan on all electrical connections and busduct enclosure
while busduct is energised and operating under maximum load conditions. A permanent
record should be kept. If readings change with time, deterioration may be taking place
and must be corrected.
 Turn off power to the busduct.
 Look for any moisture or signs of previous wetness or dripping onto the busduct or onto
connection boxes from leaky roofs, pipes, sprinklers or other sources of moisture. Look
for any recent changes in sprinklers or other plumbing that might now be a source of
trouble to the busduct.
 Seal off any cracks or openings which have allowed moisture to enter the busduct or its
connection boxes. Eliminate source of any dripping onto the busduct and any other source
of moisture.
 Replace or thoroughly dry and clean any insulating material which is damp or wet or
shows accumulation of deposited material from previous wettings.
 If there is appreciable accumulation of dust, clean it off by using a brush, vacuum cleaner,
or clean lint-free rags. In order to avoid blowing dust into busduct joints, circuit breakers,
or other equipment, do not use a blower or compressed air.
 Carefully inspect all visible electrical joints and terminals.
 Visually check connections to be certain that they are clean and secure. Loose and/or
contaminated connections increase electrical resistance which can cause overheating. Such
overheating is indicated by discoloration or flaking of insulation and/or metal parts. Pitting
or melting of connecting surfaces is a sign of arcing due to a loose or otherwise poor

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 connection. Parts which show evidence of overheating or looseness should be cleaned or
replaced if damaged, contact manufacturer before re-torquing joint bolts.
 Check the insulation resistance prior to re-energizing the busduct. A permanent record
should be kept of resistance readings. If readings decrease appreciably with time,
deterioration is taking place and must be corrected. (Contact the manufacturer).
 Indication should be provided to prohibit entry of unauthorized people in electrical shaft.
Furthermore, all shaft/gallery area should be closed by door and locked to avoid entry
of unauthorized people.

CONCLUSION

Sandwich busduct is a very important modern tool for power transmission which offers the
techno-economical solution for many problems of electrical engineers while planning,
erection and maintaining the transmission network. With the network and distribution
requirement growing up day by day, traditional cables will soon be history and busducts will
continue to gain importance. Busduct will be an inevitable and integral tool of the power
systems in future and should has to be greatly introduced and used at large scales in MES all-
over the country as a replacement of the traditional power cables.

REFERENCES
 https://webstore.iec.ch/publications
 https://assets.new.siemens.com/siemens/assets/api/uuid:0edb5716-e3d7-44d0-b74d-
ee21a0744b9b/manual-sivacon-8ps-installing-with-li-en-2017-04-05.pdf
 https://corpwebstorage.blob.core.windows.net/media/41752/busbar-trunking-
system.pdf
 https://www.es-inter.co.th/wp-content/uploads/2017/01/8.pdf
 https://www.lntebg.in/products-services/products/low-voltage-products/busbar-
trunking-system
 https://cselectric.co.in/wp-content/uploads/2020/03/Sandwich-Catalog.pdf

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