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DOCUMENT TITLE:

CABLE SIZING AND VOLTAGE DROP CALCULATION

PROJECT TITLE

INDEPENDENT DEEPWATER PETROLEUM TERMINAL AT PENGERANG, JOHOR DARUL TAZIM

PROJECT OWNER

PENGERANG INDEPENDENT TERMINALS SDN. BHD.

CONTENTS
1.0 2.0 3.0 4.0 5.0 5.1 5.2 INTRODUCTION .............................................................................................. 3 CODES AND STANDARDS ............................................................................. 3 REFERENCE DOCUMENTS ............................................................................ 3 GENERAL......................................................................................................... 3 TYPICAL CALCULATIONS .............................................................................. 5 CABLE SIZE FROM 601-DB-001 TO MOTOR ................................................. 5 CABLE SIZE BETWEEN DISTRIBUTION BOARD AND LIGHTING FIXTURE (JETTY AREA) .................................................................................................. 8 5.3 SUMMARY ..................................................................................................... 10

1.0

INTRODUCTION

This Document covers the basic calculations to calculate the cable sizing and voltage drop calculation from Distribution board to Loads.

2.0

CODES AND STANDARDS

VTS

Vopak Technical Standards

3.0

REFERENCE DOCUMENTS Electrical Design Basis Overall Lighting Layout - Jetty DH0008-ENG-E-DA-0001 DH0008-ENG-E-LA-0301

4.0

GENERAL

Cable sizing calculations are done based on the following criteria

Continuous current carrying capacity. Steady state voltage drop. Cable short circuit thermal capability. Motor starting voltage drop.

Cable continuous current carrying capacity

Full Load current (FLA)

_ Load (KW) x1000__ ____ 3 System Voltage x Power Factor x efficiency

Cable Site Rating = (Cable Current Carrying Capacity) X (Group Derating Factor) X Conductor per phase) Steady State Voltage Drop The voltage drop at steady state is given by the following formulae: For three phase AC Power system,

(No. of

. Vd = 3 X IFLX (Rcos+ X Sin) x L x 100% Vn x 1000 Where, Vn Vd IFL Cos Sin R X L = Nominal voltage = Percentage of Voltage Drop = Full load current = Active Component = Reactive Component = Resistance (ohm/Km) = Reactance (ohm/Km) = Estimated cable length (m)

For single phase AC power systems, VdAC = 2x IFLx (Rcos+ X Sin) x L x 100% Vn x 1000

Motor Starting Voltage Drop The voltage drop during starting is given by the following formulae: Vdst = 3 X IstX (Rcosst + XSinst) x L x 100% Vn x 1000 = Nominal Voltage = Percentage of voltage drop = 6x Full load current for DOL starting motors = Starting power factor (pf) = Resistance (ohm/Km) = Reactance (ohm/Km) = Estimated cable length (m)

Where, Vn Vdst Ist cosst R X L

Short circuit thermal capacity Short circuit current carrying capacity is assessed from the following formulae: I = = 224(A) (In (230 + 1/230+0)) t 142xA t

Where,

A I T 1 0

= = = = =

Cross-sectional Area of the conductor (mm2) Short circuit current (A) Total fault clearance time (seconds) Maximum permissible temperature at short circuit 250 C Maximum permissible continuous operating temperature 90 C
0 0

For cable laying the overall dearating factor comprises of two components: a. De-rating for ambient temperature(DT) b. De-rating for grouping (DG) Overall derating factor= [DT] X [DG]

5.0

TYPICAL CALCULATIONS

5.1

CABLE SIZE FROM 601-DB-001 TO MOTOR

Motor description Quick Release Hook Tag no.: 601-MD1

Rating: 5.5KW, 415V, 3-Phase, 50-HZ motor Motor power factor (running) Motor power factor (Starting) Motor efficiency = = = 0.85 0.3 85% (Assumpt.)

Rated current

5.5x1000 3x415x0.85X0.9

10A

5.1.1
-

Continuous current carrying capacity

The cables are laid on the cable ladder. The basic ambient temperature is assumed at 35 C.
0

Overall derating factor = Derating for ambient temperature (DT) x Grouping factor (DG) Overall derating factor = = Cable selected: 1 run of 3Cx6mmsq. Ampere rating for 1 run of this cable The derated current carrying capacity, ID = = = 48A 48X0. 7 33.6A [ DT ] X [ DG ] 0.7

Derated current is greater than the full load current of the motor.

5.1.2

Voltage Drop:
As per design basis the maximum voltage drop allowed from MCC/Switch Board to motor is Under Starting Condition Under Running Condition = = 20% 5%

For Motor Cos Cos (running) (starting) = = = = 0.85 0.3 10A 60A (6 times of full load current)

Running Current (IFL) Starting Current (IST) For 3Cx6mm cable Resistance Reactance Length (L)
2

= = =

3.93 (ohm/Km) 0.0837 (ohm/Km) 185M

Running condition

For three phase AC power systems, VdAC = 3x IFL x (Rcos+ X Sin) x L x 100% Vn x 1000 3x 10x (3.93x0.85+ 0.0837x0.53) x 185 x 100% 415 x 1000

= Starting condition

2.61%

VdAC

3x ISTx (Rcos+ X Sin) x L x 100% Vn x 1000 3x 60x (3.93x0.3+ 0.0837 x0.95) x 185 x 100% 415 x 1000 5.8%

Voltage drop from Switch board to motor is lower than the permissible value.

5.1.3

Short Circuit rating

The short circuit rating for 0.3 second is given by IT = 142x6/0.3 = 1555.53KA Since, Current carrying capacity of the cable is greater than derated current. Voltage drop from distribution board to Motor is lower than the permissible values Hence, 1 x 3C x 6mm cable meets the requirement.
2

5.2

CABLE SIZE BETWEEN DISTRIBUTION BOARD AND LIGHTING FIXTURE (JETTY AREA)

From 600-DB-003-SL to lighting Fixture The system consists of 250W High pressure Sodium Luminairies mounted on poles 19M apart. There are 11 fixtures total in the loop, fixtures wired to alternate phase wires. Typical wiring diagram for the lighting branch circuit and distances between the poles are shown in the fig 1.

Rating of fixture No. of fixtures Total Load Rated Current Power Factor Selected MCB rating

: : : : : :

250W 10 2500W 10.86A 1 16A

5.2.1

Continuous current carrying capacity The cables are laid on the cable ladder. The basic ambient temperature is assumed at 35 C. Overall derating factor = Derating for ambient temperature (DT) x Grouping factor (DG) Derating for cable laid on ladder supports Overall derating factor = = = = 0.75 (As per UNIVERSAL vendor catalogue)
0

[DT ] X [ DG ] 0.75x 1.06 0.8 = = = MCB rating / Overall derating factor 16/0.8 20A

The derated current carrying capacity, ID

Cable selected: 1 run of 4Cx10mmsq. Ampere rating for 1 run of this cable = 66A

Current carrying capacity of the selected cable is greater than derated current. 5.2.2 Voltage Drop As per design basis the maximum voltage drop allowed from Lighting Distribution Board to furthest light fitting of a circuit is 5%

For single phase AC power systems, VdAC = 2x IFLx (Rcos+ X Sin) x L x 100% Vn x 1000

Fig 1

a) Total load in R phase For 4Cx6mm cable Resistance Reactance Cos IFL Length (R phase) Voltage drop in R phase Vd
2

1000W

= = = = =

3.93 (ohm/Km) 0.0837 (ohm/Km) 1 4.35A 265M

2x4.35x (3.93x1) x265x100% 230x1000

3.94%

b) Total load in Y phase For 4Cx6mm cable Resistance Reactance Cos IFL
2

750W

= = = =

3.93 (ohm/Km) 0.0837 (ohm/Km) 1 3.26A

Length (Y phase) Voltage drop in Y phase Vd

227M

2x3.26x (3.93x1) x227x100% 230x1000

2.53%

c) Total load in B phase For 4Cx6mm cable Resistance Reactance Cos IFL Length (B phase) Voltage drop in B phase Vd
2

750W

= = = = =

3.93 (ohm/Km) 0.0837 (ohm/Km) 1 3.26A 246M

2x3.26x (3.93x1) x246x100% 230x1000

2.74%

Recommendations, Current carrying capacity of the cable is greater than derated current. Voltage drop from distribution board to furthest light fitting of a circuit in each phase is lower than the permissible values Hence, 1 x 4C x 6mm cable meets the requirement.
2

5.3

SUMMARY

Cable size & Voltage drop calculations for individual Motor and Street lighting fixtures in jetty area are summarized in attached Annexures. Annexure 1 Annexure 2 Note: 1. Cable lengths are based on "Overall Lighting Layout-Jetty" Dwg.no. DH0008-ENG-E-LA-0301 Rev.2. Voltage drop and cable sizing calculations for motors. Voltage drop & cable sizing calculations for street light fixtures.