I r . H. P. Looi ( me k t r i c o n @g ma i l . c o m) B. Eng ( Hons ) , FI EM, J ur ut er a Gas Cable Sizing Fundamentals and El e c t r i c a l LV St a n d a r d Ar mada Hot el , Pet al i ng J ay a 23 r d Augus t 2014 P a r t 1 C i r c u i t D e s i g n Cable sizing is a fundamental skill set required of the design engineer. Unfortunately the theory and empirical basis on which cable sizing rest on is not well understood amongst practicing engineers. Such gaps in knowledge may have implication in the design of wiring systems particularly on the safety of wiring systems (particularly thermal safety). This Presentation provides an introduction to basic concepts in sizing of cables in electrical (LV) system based on the IEC standards. The presentation is based on the handbook published and is in the following logical procession: 2 SYNOPSIS 23 r d August 2014 1. Introduction 2. Scope 3. General Design Procedure (design road map) 4. Earthing system 5. Cable types & installation method 6. Circuit configuration 7. Conductor sizing 3 THE SPONSOR WIRING HANDBOOK 23 r d August 2014 The International Copper Association Ltd. (ICA) is a non-profit organization promoting the use of copper worldwide . ICA increases awareness and usage of copper by communicating its unique attributes as a sustainable element an essential to life, science and technology, and a higher standard of living. ICA Southeast Asia established by ICA in 1992 acts as a strategic and networking base for regional copper and associated industries associations.
This handbook is distributed FREE courtesy of the sponsor 5 INTRODUCTION ROAD MAP TO IEC60364 Load Estimation 23 r d August 2014 L.V. Wiring Design Circuit Configuration Installation Method Cable Selection Protection Device Earthing Equipment Selection Verification 23 r d August 2014 8 VOLTAGE STANDARD 23 r d August 2014 Malaysian Standard Voltages It is a misconception that Malaysia Standard Voltage is at 415V/240V ! As of 1 st January 2008, Malaysia Standard Voltage is declared at 400V/230V Refer ST link for the official notification. Rationalisation of voltage is to bring Malaysia in line with other member countries of the IEC. Singapore and the UK has already converted to 400V/230V from the old 415V/240V. Other IEC member countries which have yet to convert are Germany / China (380V/220V) and India (415V/240V). Practitioners must therefore design power distribution system to 400V/230V. 23 r d August 2014 Malaysian Standard Voltages at 400V/230V +10%, -6% Major reasons for rationalising to 400V/230V Standardisation among IEC countries. Multiple certification due to different voltage levels is avoided or minimised. Most motors and fluorescent light fittings works most efficiently within the voltage band of 210V to 220V. Thus reducing to 220V will Save energy Prolong life-span of electrical equipment. Electrical power distribution system should be designed to 400V/230V ! Change all reference in specifications to 400V/230V. Specify transformers at nominal 11kV/420V (not 11kV/433V). Check cable sizing as 400V/230V incur about 4% higher current. 9 VOLTAGE STANDARD 10 VOLTAGE STANDARD Version 3 Published in 2013! 23 r d August 2014 23 r d August 2014 11 THE DESIGN WORK FLOW 23 r d August 2014 23 r d August 2014 13 EARTHING SYSTEM 60364 - Part 1; 312 2 Letters definition: 23 r d August 2014 14 EARTHING SYSTEM 23 r d August 2014 Network / Operation Criteria System Chosen / Preferred Service Criteria Competent Maintenance Continuity of service critical Available IT System preferred Continuity of service critical Not consistently available No satisfactory solution IT system preferred as discriminitive trippings are easier to implement and damages less with respect to TN system Continuity of service NOT critical Available TN-S system preferred (rapidrepairs and extension easily performed. Continuity of service NOT critical Not available No satisfactory solution. IT system preferred. Fire hazard critical Available IT system and use of 5mA RCD or TT system preferred. Special feature, very long networks Assumed available TT preferred Special feature, standby power supply Assumed available TT preferred Special feature, load sensitive to high currents (e.g. motors) Assumed available TT preferred; IT can be acceptable Special feature, low natural insulation (furnace) OR very large HF filters (computers) Assumed available TN-S preferred Special feature, control and monitoring systems Assumed available IT for continuity of services; TT for enhanced equipotential 15 EARTHING SYSTEM 23 r d August 2014 16 EARTHING SYSTEM SIZING OF P.E. (TT)
60364-5-54, 312 : For TT system, PE need for exceed 25mm (copper) 35mm (aluminium) As TT system effectively DO NOT have PE cables within the distribution system, this may presumably mean the earth electrode or frame earth system.
23 r d August 2014 Cross sectional areas of line conductors S (mm) Minimum cross sectional area of the corresponding protective conductor (mm) If the protective conductor is of the same material as the line conductor If the protective conductor is not of the same material as the line conductor S < 16 S K 1 /K 2 x S 16 < S < 35 16 a K 1 /K 2 x 16 S > 35 S/2 a K 1 /K 2 x S/2 Where K 1 is the value of k for the line conductor, selected from table A54.1 or from the tables of IEC50364-4-43 according to the resistance of the conductor and insulation. K 2 is the value of k for the conductor selected from tables A 54.2 to A54.6 as applicable a for a PEN conductor the reduction of the cross section area is permitted only in accordance with the rules for sizing of the neutral conductor (see IEC 60364-5-52). 17 EARTHING SYSTEM SIZING OF P.E. (TNS) 60364-5-54, 543 For TN-S system (method 1): 23 r d August 2014 18 EARTHING SYSTEM SIZING OF P.E. (TNS) S = PE size (mm); I = prospective fault current rms; t = operating time of protection device; k = factor based on conductor material and insulation. 60364-5-54, 543 For TN-S system where the protective device afford disconnecting time NOT exceeding 5 seconds, the following formula may apply: 23 r d August 2014 19 EARTHING SYSTEM SIZING OF P.E. (TNS) Case : Cal cul at i ng I t f or PE: From the above, we note that for up 15kA rating table 54.3 sizing for PE cable will be acceptable in terms of energy-let-through for both gG fuses and MCB class C and B types. 4x16mm PVC + 1x16mm PVC (PE) 30A CB SCI=10kA 70C PVC cables k= 115 SC I= 3 kA 5 kA 6 kA 10 kA 15 kA 25 kA 30A MCB class C, trip time t= 0.1 s 0.01 s 0.01 s 0.01 s 0.01 s 0.01 s S min size of PE cable (mm) 8.25 4.3 5.2 8.7 13.0 21.7 32A gG Fuse, trip time t= 0.01 s 0.01 s 0.01 s 0.01 s 0.01 s 0.01 s S min size of PE cable (mm) 2.61 4.3 5.2 8.7 13.0 21.7 23 r d August 2014 23 r d August 2014 21 CABLE TYPES Cable types and installation methods have implication for cable sizing and Ampere capacity. IEC60364-5-52 : Cable Selection can be summarised: 23 r d August 2014 22 CABLE TYPES ASSESSING CONDITIONS Part 5-51 defines environmental classes for use in defining installation and equipment selection criteria: A A 2 Number severity index 2 nd alphabet Specific conditions A = Environment B = Utilisation C = Building Specific conditions of environment usage etc are coded. Later prescription in standards specify technical conditions concerning conditions code. 23 r d August 2014 23 CABLE TYPES ASSESSING CONDITIONS External influences Selection considerations AA4, and AA5 Ambient temp. -5C to +40C Normal cable insulation PVC, or XLPE AD5 to AD7 Presence of water Cable jointing glands to be IPX5 and better, extruded inner sheath for cables for AD7 (submerged) AE5 and AE6 Dusty atmosphere Cable jointing glands to be IP6X, bare conductor on insulator not recommended. AG3 Mechanical stress Underground cables, mechanical protection of cables, sheathing of cables, armouring of cables, cable in ducts AH2 Vibrations Connections to motor; termination lugs, cable slack to allow for vibration AM1 Harmonics Mitigations for harmonics; Annex D in 60364-5-52 23 r d August 2014 24 CABLE TYPES ASSESSING CONDITIONS External influences Selection considerations AN3 Solar radiation Cable sheath or insulation which are immune against UV radiation (PVC sheath or insulation not permitted). AP3 and AP4 Seismic effect Cable tray preferred over conduit, slack in cable run etc. BD2 and BD4 Emergency evacuation; difficult exit Low smoke (LSZH) cables BE2 Fire risk Fire rated cables for essential services; LSZH cables CA2 Presence of combustibles Fire rated cables for essential services; LSZH cables CA2 and BE2 Combustibles and explosion risk Design to IECEx standard IEC 60079 series. 23 r d August 2014 25 CABLES FOR FIRE & SMOKE CONDITIONS Flame retardant cables do not promote or propagate the spread of fire. Flame retardant cable installation is specified under conditions of emergency evacuation (BD2 and BD4 external influences). These conditions of emergency evacuation also apply in building spaces designated as fire escape routes or emergency evacuation routes under life safety standards for building design.
The degree of flame retardant required will depend on the designed evacuation-time of the escape routes. The test for compliance to flame retardant properties are defined in the IEC 60332 series: IEC 60332-1 & 60332-2; flame propagation test on single cable is the most basic flame retardant test (whilst Part 1 specify 1kW flame for general insulated cables, Part 2 specify diffuse flame for single insulated small cables); IEC 60332-3; specify more stringent flame propagation test on bunched cables. 23 r d August 2014 26 CABLES FOR FIRE & SMOKE CONDITIONS Low Smoke, Zero Halogen (LSZH) cables reduces smoke with zero halogen emission. Classes of cables listed as Low Smoke Flame Retardant (LSFR) or Low Smoke Zero Halogen (LSZH) are defined by the following test standards: The test for Low Smoke is the smoke density test of IEC 61034; The test for halogen emission is specified in IEC 60754-1; and The test for degree of acidity of is specified in IEC 60754-2. 23 r d August 2014 27 CABLES FOR FIRE & SMOKE CONDITIONS Fire Resistant (FR) cables can maintain circuit integrity even in the presence of a fire. The test for fire resistive behaviour is specified in IEC 60331 fire integrity tests. FR cables are mandatory where essential services (e.g. fire fighting services, fire lifts etc) require circuit survivability even during a fire emergency). 1. LSFR, LSZH sheath 2. Binder tape 3. Filler, non-hygroscopic 4. Insulation, XLPE-FR 5. Mica tape (fire resistant barrier) 6. Conductor, solid or stranded. 23 r d August 2014 28 CABLES FOR FIRE & SMOKE CONDITIONS 23 r d August 2014 29 CABLES FOR FIRE & SMOKE CONDITIONS 23 r d August 2014 30 CABLE TYPES 23 r d August 2014 31 CABLE TYPES COMMON DEFECTS Conductors and cables Bare conductors Insulated conductors Sheathed cables (including armoured and mineral insulated) Multi core Single core M e t h o d
o f
I n s t a l l a t i o n
Without fixings NA Clipped direct Conduit systems Cable trunking systems (including skirting trunking, flush floor trunking)
1
Cable ducting systems Cable ladder, cable tray, cable brackets
On insulators NA NA Support wire permitted not permitted NA not applicable or not normally used in practice Table 5A Cable installation method and cable types from IEC 60364-5-52 23 r d August 2014 3. Conduit embedded in concrete are of the wrong grade (conduit not properly graded will crack when laid in concrete). 4. No proper junction boxes and/or terminal boxes. 5. Trunking and/or conduit overloaded. 6. Splicing/jointing of cables without proper terminal box.
Some Common Defects 1. PVC conduit system are substandard and are NOT certified to electrical grade. 2. PVC conduit and/or cables laid in condition where continuous sunlight occurs (PVC will deteriorate in the presence of UV light). PVC products should NOT be installed exposed to sunlight. No proper evaluation on fire- rating of cables in complying with fire properties. 32 CABLE TYPES COMMON DEFECTS 23 r d August 2014 23 r d August 2014 34 CIRCUIT CONFIGURATION EARTHING 23 r d August 2014 35 CIRCUIT CONFIGURATION 23 r d August 2014 36 CIRCUIT CONFIGURATION 23 r d August 2014 37 CIRCUIT CONFIGURATION 23 r d August 2014 38 CIRCUIT CONFIGURATION 23 r d August 2014 39 CIRCUIT CONFIGURATION 23 r d August 2014 40 CIRCUIT CONFIGURATION Cable Sizing For Safe Power System Based o n I E C S t a n d a r d s I r . H. P. Looi ( me k t r i c o n @g ma i l . c o m) B. Eng ( Hons ) , FI EM, J ur ut er a Gas Cable Sizing Fundamentals and El e c t r i c a l LV St a n d a r d Ar mada Hot el , Pet al i ng J ay a 23 r d Augus t 2014 P a r t 1 C i r c u i t D e s i g n Intermission-Continue to Part 2,,,