Cables Theory

1
CABLES-DESIGN ASPECTS.
INDEX FOR TABLES

TABLE - 1
SUBJECT
TAB
LE
NO
INDEX
SYMBOL CODES FOR CABLES
EXAMPLE OF USAGE OF SYMBOLS
OPERATING TEMPERATURE CONDITIONS
COPPER CONDUCTOR ,PVC CABLES FOR
PANEL WIRING CURRENT RATINGS
COPPER CONDUCTOR ,PVC CABLES
CABLES LAID IN AIRCURRENT RATINGS
1
2
3
4
5
ALUMINIUM CONDUCTOR ,PVC CABLES

CURRENT RATINGS
GROUP RATING FACTORS. (G R F )
6,7,8
TABLE -3
SHORT CIRCUIT RATINGS OF
CONDUCTORS FOR ONE SECOND
DURATION ( KILO AMPS
GENERATOR KVA RATINGS--- CABLE
SIZES
(1.1 KV, 3 CORE/3.5 CORE COPPER/
ALUMINUM CONDUCTOR/ PVC
10
Css\F:\Design Manual\d.m-cables\cablestheory.doc
GENERAL
CURRENT RATINGS OF CABLES.
The current ratings of Cables depend upon the following.

1) Type of Insulation. PVC or XLPE etc.
2) Size- Sq mm ./ No of cores.
3) Conductor material -Copper /Aluminium .
4) Armoured /Unarmoured..
5) Method laying open/buried in ground/in trenches/single run or multiple runs..
6) Ambient Temperature.
7) Maximum Conductor Temperature for Continuous operation
( i ) PVC 70 C ( ii ) XLPE 90 C
PVC Cables.
Reference Standard : IS 1554/Part I /1988.
The following Symbols are applicable
TABLE - 2.
A
Aluminium Conductor
Y
2Y
PVC Insulation
Insulation of thermoplastic
polyethylene(PE)
2X
Insulation XLPE
W
Steel Armour-Round Wire
F
Steel Armour-Strip
AW Aluminium wire Armour.
AF
Aluminium strip Armour
Y
PVC outer Sheath
Copper Conductor No symbol
TABLE - 3
Ex: AYWY means
A
Aluminium Conductor
Y
PVC insulation
W
Steel Round Wire Armour
PVC Outer Sheath.
Assumptions made in arriving at the cable Sizes.

TABLE - 4
Max Conductor Temperature
70 C
Ground Temperature
30 C
Ambient Air Temperature

Depth of Laying (to the highest point of cable
laid direct in the ground to the top surface of
ducts )
40 C
75 cm
STEP BY STEP PROCEDURE IN SIZING OF CABLES.

PVC /Aluminum conductor.
Data Required:
1) Continuos Current Rating Amps.
2) Short Time Current Rating/Fault level of the system where the cable is to be
used.-KA rms / Secs .
The following example illustrates.
To find the size for a 100 KVA/415 Volts rating( 3 Phase 4 Wire System)
Fault Level 10 KA rms/1.0 Secs.
Ambient Temperature 45 C
1. Calculate the continuos current = {100x 1000 } =139 Amps
{ 3 x415 }
.
Since the system is 4 wire 3.5 Core Al Conductor is to be used..
From the Cable Manufacturers Tables
3.5 Core 95/50 Sq.mm cable has current rating of 155/165 Amps in air and in ground
respectively.
The Cable is laid in ground 100 cms below.
Following Rating factors are to be applied.
(1) Variation in Ambient Temperature :0.79 (from cable catalogues)
(2) Since the cable is laid in ground the ground temperature is considered 45C.
(2). Depth of laying 0.97 (from tables)
Combined rating factor =0.79x 0.97 =0.7663
The current rating of the cable =0.7663x165=126.44.
Hence the chosen size is not O.K.
Consider the next higher size 120/70 Sq mm.
The rating of this Cable is 185 amps when laid in ground.
Applying the rating factor the current Rating = 185 x 0.7663=141.76 amps..
The value is to be checked from the point of view of S T C also.
The following formulae are applicable.
q = 13.1x Ixt Sq mm. This is for an initial Temperature of 65 C & Final
Temperature of 160C.) ( For Aluminium conductors)
Temperature of 160C. (For Copper conductors)
Temperature of 250C. (For Aluminum conductors)
Temperature of 250C. (For Copper conductors)
I = S.C.Current kA rms.
t= duration in Secs
q= (13.1) x (10). 1.0 =131 Sq mm.
We have to use 131 Sq mm.
The nearest standard size is 150 Sq mm
Cable Size Chosen is 3.5x150 Sq mm..
TABLE-5
COPPER CONDUCTOR PVC INSULATED UNSHEATHED 650/1100 V,
SINGLE CORE CABLE FOR PANEL BOARD WIRING. ALLOWABLE TEMP
:70C,
( CABLE AS PER IS :694/1990
Area in
Sq mm
Cable dia
approx
(mm)
Conductor dia
(single solid)
Current
Rating in
amps
Max DC
Resistance
/Km at 20 C
AWG No
SWG
No(approx)
0.5
2.2
0.81
39
20
21
20(0.66 Sq
mm)
0.75
2.5
1.02
26
18
19(0.81 Sq
mm)
1.0
2.6
1.15
11
19.5
17
1.5
2.9
1.45
14
13.3
15
2.5
3.5
1.83
19
7.98
13
4.0
4.3
2.30
26
4.95
11
6.0
5.3
2.91
31
3.3
10
6.7
3.66
42
1.91
18(1.17 Sq
mm)
17
16(2.07 Sq
mm)
15
14(3.24 Sq
mm)
13
12 (5.48 sq
mm)
11(6.82 Sq
mm)
10(8.3 Sq
mm)
9(10.5 Sq
16
8.2
4.62
57
1.21
25
10.0
5.83
71
0.78
mm)
8 (13 Sq mm)
7( 15.7 Sq
mm)
6 (18.7 Sq
mm)
5 (22.8 sq
mm)
4(27 sq mm)
3(38.6 sq
mm)
35
50
11.3
6.54
13.5
91
8.25
120
70
153
95
185
0.554
0.386
1(42.41 Sq
mm)
1/0
2(27 sq mm)
1(45.6 sq
mm)
TABLE 6 CURRENT
RATINGS OF 1.1 KV 3 CORE/3.5

CORE COPPER CONDUCTOR, PVC Insulated ,Inner
sheathed , Armoured/Un Armoured PVC Cables
( REF :ABB SWITCHGEAR MANUAL -TABLE 13-43)
PVC Insulated ,Inner sheathed , Armoured /Unarmoured PVC Cables, in AIR,
Ambient Temp = 30 C, Max Operating Temp = 70 C
Area Sq mm
1 Core
2 Core Amps
3/ 3.5/ 4 Core
Short circuit
Amps
Amps
current Rating
KA for
1.0sec=Area
of cross
section8.7
1.5
2.5
4
6
10
16
25
35
50
70
95
20
27
37
48
66
89
118
145
176
224
271
20
27
35
45
60
78
105
125
155
195
230
17
24
30
39
52
66
96
110
135
165,
200
0.17
0.29
0.46
0.69
1.15
1.84
2.87
4.0
5.75
8.04
9.6
Deleted: -
120
150
185
240
300
400
500
314
361
412
484
265
305
350
410
465
530
235
265
305
355
400
455
12.2
15.25
18.8
24.4
30.49
38.11
47.65
TABLE -7
CURRENT RATINGS OF 1.1 KV 3 CORE/3.5 CORE
ALUMINIUM CONDUCTOR, PVC Insulated ,Inner sheathed
, Armoured/Un Armoured PVC Cables
2
Size mm
16
25
35
50
70
95
120
150
185
240
300
400
500
Current ratings
Direct in ground Amps
Armoured/ Un
Armoured
60
76
92
110
135
165
185
210
235
275
305
335
350
Current ratings in Current ra

Ducts - Amps
Air - Amp
Armoured/ Un
Armoured
50
63
77
95
115
140
155
175
200
235
260
290
310
Armoured
Armoured
51
70
86
105
130
155
180
205
240
280
315
375
410
GROUP RATING FACTORS. (G R F )

When ever cables are laid in groups the total current carrying capacity has to be
reduced by the group rating factor.
G R F for Single Core Cables laid in Trefoil formation
TABLE -8
(a) Cables laid in ground in horizontal formation
No of Trefoil in
Spacing between Trefoils
group
Touching 15 Cms 30 Cms > 30 Cms
0.88
0.85
0.81
0.78
2
0.81
0.77
0.71
0.68
3
0.76
0.72
0.65
0.61
4
0.73
0.68
0.61
0.56
5
TABLE -9
(b) Cables laid in Trefoil ducts in horizontal formation
No of Trefoil in
Spacing between Trefoils
group
Touching 45Cms 60Cms
0.91
0.90
0.87
2
0.86
0.83
0.79
3
0.82
0.79
0.74
4
0.80
0.76
0.71
5
(c) Cables laid on racks/Trays in covered trench with removable covers where air
circulation is restricted, trefoils are separated by Two cable dia horizontally
and the trays are in tiers with 30Cms gap between them.
TABLE -10
No of Trefoils in horizontal
No of
formation
racks/trays in
tiers
1
2
3
0.91
0.90
0.95
1
0.86
0.85
0.90
2
0.82
0.83
0.88
3
0.80
0.81
0.86
6
(d) Cables laid as at (c) but in open air.
TABLE -11
No of Trefoils in horizontal
No of
formation
racks/trays in
tiers
1
2
3
0.98
0.95
0.94
0.93
1.0
1.0
1.0
1.0
1
2
3
6
0.96
0.93
0.92
0.90
G R F for Multi Core Cables

(A) Cables laid inside concrete trenches with removable cover, on cable trays
where air circulations is restricted. The cables spaced by one cable diameter and
trays in tiers by 300 mm. The clearance between the wall and cable is 25 mm.
TABLE -12
No of
cables
trays in
tiers
1
No of cables
1
0.95
0.90
0.88
0.85
0.84
0.90
0.85
0.83
0.81
0.80
0.88
0.83
0.81
0.79
0.78
0.86
0.81
0.79
0.77
0.76
(B) Cables laid on cable trays exposed to air, the cables spaced by one cable
diameter and trays in tiers by 300 mm. The clearance between the wall and cable is
25 mm.
TABLE -13
No of
cable
trays in
tiers
1
Spacing of cables
1
1.0
0.98
0.98
0.96
0.92
1.0
0.95
0.95
0.93
0.89
1.0
0.94
0.94
0.92
0.88
1.0
0.93
0.90
0.90
0.86
10
(C) Cables laid on cable trays exposed to air , the cables touching and trays in
tiers by 300 mm.The clearance between the wall and cable is 25 mm.
TABLE -14
No of
cable
trays in
tiers
1.0
0.84
0.80
0.75
0.73
1.0
0.80
0.76
0.71
0.69
1.0
0.78
0.74
0.70
0.68
1.0
0.76
0.72
0.68
0.66
Spacing of cables
(D) Cables laid direct in ground in horizontal formation.

TABLE -15
Spacing of cables
No of
cables
touching 15Cms 30Cms
45Cms
in group
2
0.79
0.82
0.87
0.09
3
0.69
0.75
0.79
0.83
0.62
0.69
0.74
0.79
0.58
0.65
0.72
0.76
0.54
0.61
0.69
0.69
(E) Cables laid in single way ducts /pipes in horizontal formation.

TABLE -16
Spacing of cables
No of
cables
touching 30Cms 45Cms
60Cms
in group
2
0.88
0.90
0.92
0.94
3
0.82
0.84
0.87
0.89
0.77
0.80
0.84
0.87
Css\F:\Design Manual\d.m-cables\cables-
theory.doc
11
5
0.74
0.78
0.82
0.85
0.71
0.76
0.81
0.84
12
TABLE -17
SHORT CIRCUIT RATINGS OF CONDUCTORS FOR ONE SECOND

DURATION ( KILO AMPS)
Normal
Area of
Conduct
or
(mm)
Copper
Aluminium
Initial Temp of conductor Initial Temp of

conductor
=65 C
=65 C
Final Temp=165C
Final Temp=165C
1.0
2.5
4.0
6
10
16
25
35
50
70
0.12
0.30
0.46
0.70
1.15
1.84
2.87
4.02
5.75
8.05
0.31
0.46
0.76
1.22
1.91
2.67
3.82
5.34
95
120
150
185
240
300
400
500
630
800
1000
10.92
13.80
17.24
21.26
27.6
34.5
46.0
57.5
72.4
91.95
114.5
7.25
9.16
11.45
14.12
18.32
22.90
30.53
38.17
48.1
61.10
76.33
Formula for calculating the magnitude of S.C Current for other durations.
I k = (I 1 / K)
Where I 1 = Short Circuit rating for 1.0 second
I k = Short Circuit rating for K Second.
K= duration in Seconds
( The above formula is valid for values of K =0.2 to 5.0 Seconds.
13
TABLE -18
GENERATOR KVA RATINGS--- CABLE SIZES
(1.1 KV, 3 CORE/3.5 CORE COPPER/ ALUMINIUM conductor ,PVC
Insulated ,Inner sheathed , Armoured/Un Armoured PVC Cables)
GENERA
OVER SIZE OF
CURRENT- Size mm2
TOR
ALL
CABLE
RATING AMPS
CABL GLAND
E-DIA -inches
3PHASE,
mm
KVA
21
6(COPPER)
15
23
35
6(COPPER)
25
23
50
10(COPPER) 23
35
90
35
63
28
1
105
70
75
36
1 3/8
112
70
80
36
1 3/8
120
120
100
43
1 3/4
175
150
125
47
2
196
185
140
52
2
224
240
160
58
2 3/4
252
300
180
64
2 3/4
200
280
400
71.5
3
250
315
350
500
750
350
440
490
700
1050
2 X 185
2 X 240
2X300
3x300
5x300
or4x400
14
WIRE TABLE FOR SOLID, ROUND COPPER CONDUCTORS
Size
Diameter
AWG
inches
Cross-sectional area
cir. mils
Weight
sq. inches lb/1000 ft
===============================================================
4/0 -------- 0.4600 ------- 211,600 ------ 0.1662 ------ 640.5
3/0 -------- 0.4096 ------- 167,800 ------ 0.1318 ------ 507.9
2/0 -------- 0.3648 ------- 133,100 ------ 0.1045 ------ 402.8
1/0 -------- 0.3249 ------- 105,500 ----- 0.08289 ------ 319.5
1 -------- 0.2893 ------- 83,690 ------ 0.06573 ------ 253.5
2 -------- 0.2576 ------- 66,370 ------ 0.05213 ------ 200.9
3 -------- 0.2294 ------- 52,630 ------ 0.04134 ------ 159.3
4 -------- 0.2043 ------- 41,740 ------ 0.03278 ------ 126.4
5 -------- 0.1819 ------- 33,100 ------ 0.02600 ------ 100.2
6 -------- 0.1620 ------- 26,250 ------ 0.02062 ------ 79.46
7 -------- 0.1443 ------- 20,820 ------ 0.01635 ------ 63.02
8 -------- 0.1285 ------- 16,510 ------ 0.01297 ------ 49.97
9 -------- 0.1144 ------- 13,090 ------ 0.01028 ------ 39.63
10 -------- 0.1019 ------- 10,380 ------ 0.008155 ----- 31.43
11 -------- 0.09074 ------- 8,234 ------ 0.006467 ----- 24.92
12 -------- 0.08081 ------- 6,530 ------ 0.005129 ----- 19.77
13 -------- 0.07196 ------- 5,178 ------ 0.004067 ----- 15.68
14 -------- 0.06408 ------- 4,107 ------ 0.003225 ----- 12.43
15 -------- 0.05707 ------- 3,257 ------ 0.002558 ----- 9.858
16 -------- 0.05082 ------- 2,583 ------ 0.002028 ----- 7.818
17 -------- 0.04526 ------- 2,048 ------ 0.001609 ----- 6.200
18 -------- 0.04030 ------- 1,624 ------ 0.001276 ----- 4.917
19 -------- 0.03589 ------- 1,288 ------ 0.001012 ----- 3.899
20 -------- 0.03196 ------- 1,022 ----- 0.0008023 ----- 3.092
21 -------- 0.02846 ------- 810.1 ----- 0.0006363 ----- 2.452
22 -------- 0.02535 ------- 642.5 ----- 0.0005046 ----- 1.945
23 -------- 0.02257 ------- 509.5 ----- 0.0004001 ----- 1.542
24 -------- 0.02010 ------- 404.0 ----- 0.0003173 ----- 1.233
25 -------- 0.01790 ------- 320.4 ----- 0.0002517 ----- 0.9699
26 -------- 0.01594 ------- 254.1 ----- 0.0001996 ----- 0.7692
27 -------- 0.01420 ------- 201.5 ----- 0.0001583 ----- 0.6100
15
28 -------- 0.01264 ------- 159.8 ----- 0.0001255 ----- 0.4837
29 -------- 0.01126 ------- 126.7 ----- 0.00009954 ---- 0.3836
30 -------- 0.01003 ------- 100.5 ----- 0.00007894 ---- 0.3042
31 ------- 0.008928 ------- 79.70 ----- 0.00006260 ---- 0.2413
32 ------- 0.007950 ------- 63.21 ----- 0.00004964 ---- 0.1913
33 ------- 0.007080 ------- 50.13 ----- 0.00003937 ---- 0.1517
34 ------- 0.006305 ------- 39.75 ----- 0.00003122 ---- 0.1203
35 ------- 0.005615 ------- 31.52 ----- 0.00002476 --- 0.09542
36 ------- 0.005000 ------- 25.00 ----- 0.00001963 --- 0.07567
37 ------- 0.004453 ------- 19.83 ----- 0.00001557 --- 0.06001
38 ------- 0.003965 ------- 15.72 ----- 0.00001235 --- 0.04759
39 ------- 0.003531 ------- 12.47 ---- 0.000009793 --- 0.03774
40 ------- 0.003145 ------- 9.888 ---- 0.000007766 --- 0.02993
41 ------- 0.002800 ------- 7.842 ---- 0.000006159 --- 0.02374
42 ------- 0.002494 ------- 6.219 ---- 0.000004884 --- 0.01882
43 ------- 0.002221 ------- 4.932 ---- 0.000003873 --- 0.01493
44 ------- 0.001978 ------- 3.911 ---- 0.000003072 --- 0.01184

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1

INDEX FOR TABLES

ALUMINIUM CONDUCTOR ,PVC CABLES

GROUP RATING FACTORS. (G R F )

The current ratings of Cables depend upon the following.

Steel Round Wire Armour

PVC Outer Sheath.

Assumptions made in arriving at the cable Sizes.

Ambient Air Temperature

STEP BY STEP PROCEDURE IN SIZING OF CABLES.

RATINGS OF 1.1 KV 3 CORE/3.5

Current ratings in Current ra

GROUP RATING FACTORS. (G R F )

G R F for Multi Core Cables

(D) Cables laid direct in ground in horizontal formation.

(E) Cables laid in single way ducts /pipes in horizontal formation.

SHORT CIRCUIT RATINGS OF CONDUCTORS FOR ONE SECOND

Initial Temp of conductor Initial Temp of

sq. inches lb/1000 ft

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