GlobalSpec has asked its users about the latest design trends and features related to Busbars and Busways. They have also shared their product applications and tips on how to buy and use these products.
See the entire survey


Q:
What are some of the applications you have used busbars or busways for?
55 answers
Answers:
Lighting busbar >40A in retail malls, shopping centres and large distribution centres for logistics/warehousing. Rising Mains systems >800A/1600A for hotels, office buildings, hospitals as distribution supplies for factories and workshops. As prime supply from transformers, generators to LV boards on Data centres at 1600 - 6300A loads.
~David C, General Management, Camberley, UK

The selection of busbars is done for LV Panels, MV panels.  The selection of Busways is done when the 1) Current is comparatively high 2) where the usage of cables is not feasible, since for higher currents, lot of parallel cables are required for each phase and bending of cables may be difficult in panels. 3) usually done between the transformer/ Generator to the first Main LV panel.

~Shrimant S, Marketing/Sales, Bangalore, India

Operation, maintenance, renovation/ upgrading of existing Busbar systems to accommodate additional outgoing feeders to reduce cost of projects (instead of procurement of new panels) for capacity expansion scheme.

~Manindra Nath Datta D, Head of Electrical Engineering wing of Haldia Dock Complex, Kolkata Port Trust., Haldia, India
As: i)Components of Bus ducts for connecting Power Control Centres to Transformers ii) Components of Power Control Centres and Motor Control Centres iii ) For Electrolytic Cells in Zinc refining in smelter
~Nagendra Mathur M, Engineering Consultant, Kolkata, India
The big new thing is diesel over electric for just about any application over maybe 400 hp. This will include construction, agriculture, and forestry and should revolutionize the industry.
~Bruce O, Design Engineer, Northfield, MN
Power distribution at low voltage level. Especially, the portion, Transformer direct coupling to LV Switch-Boards. That area needs to be neat & tidy, reliable & as simple as possible.
~Johnny K, Builder/Contractor, Vietnam

Used busbars extensively in Low Voltage Switchgear.

~Edwin P, General Manager
132kV, 66kV, 33kV and 11kV substations. I have used flexible aluminium and copper, tubular aluminium and copper and aluminium and copper flat bar and fittings.
~Engineering, Design, Camperdown, Australia

Power distribution in high rise buildings, transformer to switchgear connections, switchgear to chiller connections, in industries etc.

~Balakrishnan Nair K, General Manager, Sharjah, United Arab Emirates
4-38kV buses everywhere to or from step up/down transformers on power plants, buses in MV substations in different industry.
~Igor B, Lead Project Engineer, Minnetonka, MN
I work for Baker Hughes in Maracaibo and we use busbars and busways to connect industrial machines to the power lines.
~Maintenance/Facilities Management, Maracaibo, Venezuela

Used in high rise buildings and for connections between transformers and generators to main switchboards.

~Engineering, Design, Doha, Qatar

Low voltage switchgear and control gear assemblies; feeders from power transformers up to 4000 amps.

~Engineering, Consulting, Ednvale, South Africa

MV Generator to transformer connection in Power Plants, MV and LV Transformer to Switchgear.

~MICHEL G, Engineering Consultant, PARIS, FRANCE

Generator connection, transformer connection, tie connection between switchboards.

~eduard K, Engineering Consultant, Haifa, israel
High tension electrical risers/distribution in hospitals and office buildings.
~Engineering, Other, Williamsburg, VA

Power distribution in multi-story buildings; power distribution boards.

~shetty U, Manufacturer, nashik, india
From transformer (LV side) output to our heater power control panel.
~Engineering, Design, Bangalore, India
To connect generator to a unit transformer Switchgear/switchboards
~stanley A, Reliability Engineer (Electrical), Nigeria

Genset connections, transformer connections, panelboard connections

~Marketing/Sales
Switchboards and Overhead systems for factory applications.
~Engineering, Design, NAPIER, New Zealand
Switchgear, motor controls, transformers, power supplies
~Jonathan B, Marketing/Sales, Richmond, IL
Custom-Built LV High Power Electrical Switchboards
~Manufacturing, Queanbeyan, Australia
Low voltage switchboards, marine / navy deliveries
~Engineer

Substations; feeder pillars; distribution boards

~bright charakupa C, Engineering Consultant, gaborone, IL
Transmission of power and distribution of power
~Ramesh M, Marketing/Sales, chennai, India
Low voltage distribution equipment, switchgear
~Engineer, Rosslyn, VA

For feeding big loads in commercial buildings.

~Engineering, Consulting, Caracas, Venezuela
Electrical switch gear and control panels.
~Technical Support/Services, QUEZON CITY, Philippines
Inside metal cells at mid and low voltage.
~Herbert M, Engineer, Santiago, Chile

CD current delivery for plating businesses.

~Engineering, Other, San Luis Potosi, Mexico
LV/MV Switchgear Panels, PCC, MCC etc.
~Srin S, Facilities Manager, Oman, Oman
For control panel internal connection.
~Amit C, Project Manager, Khanvel-silvassa, India
Power Distribution in vertical risers.
~See Fong H, Engineer, Singapore, Singapore
Buildings, power plants, substations
~dennis C, General Management, singapore, singapore
Lightning and EMP damage mitigation
~Mike L, Research & Development, Lockhart, TX
Power Distribution & Switchboards
~Sunil P, Marketing/Sales, Pune, India
LT Control Panels & Bus Trunkings
~Engineering, Design, Gwalior, India
LT panels & trunking distribution
~Engineering, Consulting, Dhaka, Bangladesh
Product reliability test stations
~Greg B, Research & Development, Oklahoma City, OK

Distribution panels; load sharing

~zubair M, Engineer, lahore, pakistan
Aircraft electrical distribution
~Engineering, Design, sarralbe, France
Primarily battery applications
~JD L, Marketing/Sales, Anahiem, CA

Networking of house wiring.

~Dorai R, Engineering Consultant, Hyderabad, India
Industrial apps, buildings.
~Project Manager

Rising main, overhead line

~Engineering, Design, Nasik, India
Electrical Control Panels
~Manufacturing, Noida, India
For metal clad switchgear
~Research & Development, salem, India
Switchgear technology
~K B, Engineer, kakinada, India
Power control centres
~KV SRIDHAR, Engineering Consultant, BANGALORE, INDIA
Manufacturing Busbars
~Deepak A, Quality Control, Ras Al Khaima, U.A.E
Large power systems
~Milwaukee, WI
Water supply plant
~Engineering, Consulting, Belgrade, Serbia-Montenegro
Panels, busducts
~suresh S, General Management, chennai, india
Thermal testing
~Lou P, Technical Support, Coraopolis, PA

Top
Q:
Please share with us any “non-standard” applications that busbars or busways have been used for.
16 answers
Answers:

This technology can be used in emergency lights with LED. With this, the light will function even if one or two LEDs go off and also can have the option of selection of lighting with slide switches. (This is only for low voltage and not for KV range).

~Dorai R, Engineering Consultant, Hyderabad, India

Working in Pakistan... most of the time, we face very poor standards of distributing the connections from main breaker... like when there will be more than one load attached on one main circuit breaker.... there we need busbars to distribute the load cables properly to decrease the line losses.

~zubair M, Engineer, lahore, pakistan

Recently I had seen Oriental Copper offer their users a new technology wherein busbars bent 180 degrees by twisting and turning thereby allowing for phase sequence to be maintained without any additional phase transfer busbars.

~Edwin P, General Manager

Outdoor use. Spotted at Bangkok Airport. From GenSet room to SwitchBoards seem to be very far apart, running direct exposure to weather.

~Johnny K, Builder/Contractor, Vietnam
Small power busbar 100A feeding computer server cabinets in small data centres.
~David C, General Management, Camberley, UK

There are requirements coming out for smaller ratings; also in single phase.

~Ramesh M, Marketing/Sales, chennai, India

Temporary power connections for short periods for construction activities.

~Manindra Nath Datta D, Head of Electrical Engineering wing of Haldia Dock Complex, Kolkata Port Trust., Haldia, India
Independent voltage & frequency selection at each test station.
~Greg B, Research & Development, Oklahoma City, OK
Use in high salt sea environment or outdoor environment.
~See Fong H, Engineer, Singapore, Singapore
DC connections in industry, high frequency
~MICHEL G, Engineering Consultant, PARIS, FRANCE
Conduction of power from Busbar to PCB.
~Engineering, Design, sarralbe, France

Naval; wind power; household applications

~IGOR M, Process Engineer, JARAGUA DO SUL, BRASIL
For furnace in glass factory
~Mohamed G, Engineering Consultant, Sharjah, U.A.E.
Circuit board stiffener
~Jonathan B, Marketing/Sales, Richmond, IL
Tap off box connectors
~Deepak A, Quality Control, Ras Al Khaima, U.A.E
Residential apps
~Project Manager

Top
Q:
Do you know of any disastrous mistakes that occurred due to the incorrect usage of busbars or busways?
22 answers
Answers:
Due to improper maintenance and upkeep there was huge flash over in bus system and in effect entire plant was shut down for one day as there was no full standby system to feed power requirement of plant.
~Manindra Nath Datta D, Head of Electrical Engineering wing of Haldia Dock Complex, Kolkata Port Trust., Haldia, India
Impedance decoupling from standing waves caused current surge, blowing out one phase of a supply.
~Greg B, Research & Development, Oklahoma City, OK
There is nothing more exciting than an arcing ground or phase to phase fault! Make sure adequate spacing or insulation is maintained between adjacent busbars and or ground!
~Engineering, Other, Williamsburg, VA
Arc flash due to failure of safety interlocks in an MCC.
~KV SRIDHAR, Engineering Consultant, BANGALORE, INDIA
Generally I have noticed that the common mistake which occurs is due to: 1. poor quality of insulation and metal casing of the busways. 2. ignorance of the design requirement and environmental condition of the installation. 3. when associated within a system like switchboard to ensure that the eddy current does not create a loop and humming which may cause the temperatures to rise within the busbars leading to deteriorating of the busbars and eventually the performance.
~Edwin P, General Manager
A-Bus bars are stored at Site in Dusty/Humid Condition, if not properly cleaned before Installation, leads to Short Circuit & Damage. B-Do NOT Try to Repair the Bus bars at Site if Damaged due to Bad Storage or Mis-handling. It is a Specialist's Job.
~Vilas P, General Management, Ras Al Khaima, UAE
Improper Joint pack installation to connect two busbars while installation may result in busbar failure due to high resistance.
~Deepak A, Quality Control, Ras Al Khaima, U.A.E
Major problems faced many times are over heating of busbars and the resultant failures of ACBs and other switch devices.
~suresh S, General Management, chennai, india

Am aware of where cast resin bar has cracked and failed due to changes in ambient temperature (3 projects in UK).

~David C, General Management, Camberley, UK
Bad connections at site made by unskilled people especially with aluminium conductors.
~MICHEL G, Engineering Consultant, PARIS, FRANCE
Yes. With ignorance, if the same bus bar is connected with two different poles.
~Dorai R, Engineering Consultant, Hyderabad, India
Tap Off units, are most often problematic due to their bulky sizes.
~Johnny K, Builder/Contractor, Vietnam
High ohmic joints forming in moderately corrosive environments.
~Mike L, Research & Development, Lockhart, TX
Improper Crossection of Busbars, Substandard supports material.
~Sunil P, Marketing/Sales, Pune, India
Flashover due to creepage of water.
~shetty U, Manufacturer, nashik, india
Don't place them below sprinklers.
~See Fong H, Engineer, Singapore, Singapore
Shorts due to lack of maintenance.
~Project Manager
Undersized it will act as a fuse.
~Jonathan B, Marketing/Sales, Richmond, IL
Busbar melting and burning
~Herbert M, Engineer, Santiago, Chile
Wrong connectors
~JD L, Marketing/Sales, Anahiem, CA
Over loading
~Mohamed G, Engineering Consultant, Sharjah, U.A.E.
Flashovers
~bright charakupa C, Engineering Consultant, gaborone, IL

Top

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