GUIDELINES FOR SIZING OF POWER CABLES

1.0

INTRODUCTION

2.0
A)
B)
C)
D)
E)
F)
G)

GENERAL GUIDELINES
Voltage grade of cable
Cable insulation
Conductor material
Armouring
Number of cores
Screening / Shielding
Single run versus Multiple runs

A)
B)
C)
D)
E)
F)

CRITERION FOR CABLE SELECTION

Current rating for continuous operation
Fault /Short circuit current withstand capability
Voltage regulation
Sheath voltage check (single core cable only)
Type of cable installation
Thermal conditions (Ambient temp., soil conditions)

3.0

4.0

FIRE SURVIVAL CABLES

5.0

CABLE SELECTION PROCEDURE DIAGRAM (FLOWCHART)

6.0

STANDARD RECOMMENDED LIST OF CABLES FOR ABB

7.0

ANNEXURES
Annexure I : Current and Fault current carrying capacity of cables
Annexure II : Derating factors for installation & laying methods

A)
B)

Rev. :

Date :

Description :

Prepared :

Reviewed:

Released :

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Introduction

Generally in any of electrical auxiliary system, for each feeder or motor circuit application,
a suitable power cable with requisite specifications such as conductor size, type of
armouring etc., has to be designed for satisfactory operation during normal and abnormal
operating conditions. These design guidelines are intended to simplify the various needs
for selection of optimum size and appropriate type of cable for the specified applications.
2.0

General Guidelines

While selecting a cable the following guidelines shall be used for specifying the type of
cable etc.
A) Voltage grade of cable: Based on System voltage and system earthing the voltage
grade of cable can be selected from the following table:
System Voltage kV

Voltage Grade of cable

Earthed (solidly earthed) Unearthed (resistance earthing)

11

6.35/11 kV

11/11 kV

6.6

3.8/6.6 kV

6.35/11 kV OR 6.6/6.6 kV

3.3

1.9/3.3 kV

3.8/6.6 kV OR 3.3/3.3 kV

0.415

650/1100 V (IS) OR
600/1000 V(IEC)

1.1/1.1 kV

B) Cable Insulation : PVC / XLPE

Type of cable insulation (PVC/XLPE) can be selected based on the max. operating
temperatures during normal and fault conditions from the following table.
TABLE : A
Cable insulation
PVC
XLPE

Max.
temp. under Max. temp under S/C
normal operations
conditions
70 Deg C
90 Deg C

160 Deg C
250 Deg C

General recommendations are:

LV(1.1kV & less) - Power & control cables - PVC/XLPE insulated cables
MV (Above 1.1kV)- Power cables - XLPE insulated cables

C) Conductor Material : Aluminum / Copper

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Selected based on ease of termination and cost economics.

recommendations are

Copper
Aluminium

:
:

Generally the

Maximum conductor size upto 10 sq.mm

Conductor size Above 10 Sq.mm

IS 1554 specifies the following for selection between solid / strandard conductors
Table - B
Cu. conductor Aluminum conductor
(sq.mm)
(sq.mm)

Type of conductor

1.5 - 6
10 and above

Solid
Solid / Strandard
Strandard

1.5
2.5 - 10
16 and above

D) Armouring : Cable armouring is generally provided for mechanical protection. Hence

wherever, mechanical loading on cables (direct or indirect) is foreseen, cables shall be
armoured type.
However general recommendation for power plant applications are all directly buried
cables and cables laid in side the switchyard shall be armoured type.
Type of armouring:

For multicore cables (as per IS 1554), where calculated diameter below armouring
does not exceed 13mm armouring shall be of galvanised round steel wire, and for
cables where calculated diameter below armouring exceed 13mm armouring shall be
of galvanised round steel wire or galvanised steel strips.

In case of single core cables armouring shall be of non-magnetic material

(Aluminium).This is because unlike in 3- core cable where the magnetic field of three
cores mutually cancel each other and hence no circulating currents are induced in the
armour .In single core cable there will not be cancellation of magnetic field & hence
circulating currents will be induced in the armour (if it is of magnetic material) which will
cause heating & will be unsafe.

E) Number of cores (single core or Multicore cables):

Single core cables are recommended for incomer feeders from transformer to
switchgear and for higher current rating feeders irrespective of voltage level. This is
being followed in view of the condition that for larger current ratings 3 core cables will
be physically larger and huge for installation. For various voltage levels ,
recommended standard sizes have been furnished in clause 6.0.

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For fuse protected feeders, multicore cables are recommended. Wherever 3 phase,
neutral is required (i.e.) switch fuse feeders in LV system 4 core/3.5 core cables are to
be adopted. For all L.V. motor feeders 4 core/3.5 core cables will be adopted wherein 3
cores are used for phases and 4th core is for earthing.

F) Screening/Shielding :
Normally screening is provided over the conductor and insulation for HV cables. In case of
insulation screening it consists basically of a semiconducting screen combined with
metallic screen. Whereas only semiconducting screen is provided for the conductor.
Shielding /screening basically helps in :

To have uniform distribution of voltage stress between conductor surface and outer
surface of insulation.
To limit electromagnetic field beyond the shield to a low value.
To minimise voltage stress on conductor surface.
To reduce shock hazards when shields are properly grounded by suitable means at
both the cable ends

G) Single Run Versus Multiple Runs :

In many cases , where large currents are to be carried the conductor size becomes very
large. Therefore in such cases parallel/multiple runs of cable (multi core/single core) are
used. Generally higher sized multi core cables are difficult to handle and have termination
problems. Standard sizes of single core and multi core cables, for various voltage
gradients are furnished in clause 6.0.
However, for smaller conductor sizes the choice between single run / multi runs cables
can be arrived at by comparing their costs.
3.0

Criteria for Selection of Cable

Critically, the following technical aspects to be satisfied on selecting cable for particular
application.
A) Current rating for continuous operation
B) Fault current withstand capability
C) Voltage Regulation (Voltage Drop)
D) Sheath Voltage check ( for 1 core cables)
E) Type of cable installation (laid in air , buried etc.)and
Thermal conditions (ambient temp., soil conditions)

A)

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Current Rating for continuous operation

The Major factors responsible for deciding the continuous current rating of a cable can be
broadly classified as following:
1) Cable selection includes
aa) Conductor Material (either copper or aluminum)
bb) Max. temperature for conductor
The following table gives the maximum conductor temperature for
adopted for cables
Cable insulation

Max. temp. under normal Max.

temp
operations
conditions

PVC
XLPE

70 Deg C
90 Deg C

under

generally
S/C

160 Deg C
250 Deg C

Note: The current carrying capacity given in the annexure I for various cables are based
on the above Maximum temperatures.
B) Fault Current / Short circuit Withstand Capacity of the cable
Depending upon the fault current magnitude and duration, the minimum conductor size
shall be arrived using the formula:
Ik =

A
k1*k2*t

Where,

Ik = Fault current in kA

A = Min. conductor area in sq.mm

t = Duration of fault current in second

k1=constant (depending upon type of conductor)

k2=constant (depending upon the temperature before and after short circuit)

k2=log(( + T2) / ( + T1))-1/2

= temperature coefficient of electrical resistance at zero deg. C

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T1= Initial temperature before short circuit in deg. C

T2= final temperature after short circuit in deg. C

1)

Value of k1 & :

Conductor Material
Aluminium
Copper (screen)
Galvanised steel (armour)
2)

Value of k1
6.76
4.41
12.8

Value of T1 & T2 :

Type of material
Armour for PVC Cables
Conductor with PVC insulation
Screen/ armour for XLPE cables
Conductor with XLPE cables
3)

value of
228
234.5
202

T1 (deg. C)
60
70
80
90

T2 (deg C)
N.A.
160
200
250

Consolidated table for value of Ik

Type of cable
k1

PVC insulated, aluminium 6.76 228

conductor

T1
70

T2
160

k2
1.94

Ik (kA)
Ik = 0.076*A
t

XLPE insulated, aluminium 6.76 228

conductor

90

250

1.56

Ik =

0.094*A
t

Copper screens

4.41 234.5

80

200

1.76

Ik =

0.0128*A
t

Galvanised steel armour

12.8 202

80

200

1.7

Ik =

0.046*A
t

wire(armour), 6.76 228

80

200

1.74

Ik =

0.0848*A
t

Galvanised steel (armour), 12.8 202

PVC

60

200

1.528

Ik =

0.051*A
t

Aluminium wire (armour), 6.76 228

PVC

60

200

1.588

Ik =

0.093*A
t

Aluminium
XLPE

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4)
Recommendations for short circuit current density of short circuit current duration
(max.) of 120 msec in breaker protected circuits:
Type of cable
Aluminium conductor, PVC
Aluminium conductor, XLPE
Copper Screen
Aluminium armour, PVC
Aluminium armour, XLPE
Galvanised steel armour, PVC
Galvanised steel armour, XLPE

Short circuit current density

(A/mm2)
219
271
369
268
244
147
132

5)
The duration of fault current can be decided based on the type of protection
provided for the particular feeder.This is because fault clearing time of protective device
determines the duration of short circuit current, the cable has to withstand. The
recommended values are :
Protective
Device
Circuit Breaker

Fuses

Fault clearing Remarks

time (msec.)
120
For cables in incomer & bus coupler circuits
the cumulative cable withstand shall be
adequate for total fault clearing time. Hence
it is not intended to select individual cables
to be capable of total fault clearing time in
such circuits
less than 20
Cable sizes are selected on the basis of
nominal rated current which is considered
adequate to withstand let through energy of
the fuse

Note: The fault current withstand capability of various sizes of cables are also included in
the annexure III for a duration of 1 sec.
Based on the type of faults and overloading, further classifications and analysis shall be
made, if required. (Ref : CEGB Modern power station practise Vol- D chapter - 6)
C)

Voltage Regulation (voltage drop)

Due to impedance of the conductor, there is voltage drop in the cable between sending
end and the receiving end. All electrical equipments in the plant are designated to operate
within specified limits of voltage regulation during normal running and starting conditions.
The permissible voltage drop in Cable portion shall be restricted to the following
generally:
- During normal running conditions :

3% Voltage drop

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- During starting

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15% Voltage drop

However the customer requirements needs to be checked for project specific application.
1)

Voltage drop calculations:

V = I * L * (R cos + X sin )
V = 3 *I * L * (R cos + X sin )

(for single phase system)

(for three phase system)

Where,

V = Voltage drop in volts

I = line current carried by the cable in Amps

L = Length of cable in kms.

R = AC resistance per unit length at Max. operating temp (70 deg for PVC, 90 deg for
XLPE) in

X = Reactance per unit length at 50 Hz in .

Cos = Power factor

Note :

In case more than single run of cable is used, then it is assumed that total current is
equally distributed among the runs

When large motors are used in the system, motor locked rotor current can cause
sustained reduction in voltage at motor terminals as well as at the bus. Therefore
motor starting current and starting power factor should be taken into account for
voltage drop calculation

2)

Maximum Length of Selected Cable:

For the given conditions and selected cable, the maximum length of cable for that
application shall be calculated for both the normal/running and starting conditions by using
the following formula
Lmax = Length of Cable x Voltage drop (permissible %)
Actual Voltage drop %
Lmax = Min (Lmax_start, Lmax_run)

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The calculated value of Lmax should be more than the actual cable route length, thereby
ensuring that the cable is adequately protected against earth faults and the voltage
regulation is within permissible limits. In case it comes out to be less than actual cable
route length, then select the next higher conductor size.
D) Sheath Voltage check ( for 1 core cables):
For single Core cables, metallic screen losses and armour losses (which occur due to
circulating currents), can be reduced by bonding the armour to earth at one end. This will
however induce certain voltage at open end. This is referred as Sheath Voltage.
The maximum permissible sheath voltages are as under:

During normal conditions : 55V

During Faulty conditions : 2kV

I) Sheath voltage during normal conditions can be calculated as follows:

Vfl = 4 * * f * Ifl *10- 7 * logn(3 * 2S / R)

volts / metre

ii) Sheath voltage during fault conditions can be directly arrived as a proportionate of Vfl.
Vsc = Vfl * Isc / Ifl

Where,

Vfl = Sheath voltage under normal conditions

f = frequency in hertz
Ifl = Full load current in amps.
S = Separating distance between centers of adjacent cable in metres
R = Radius of armour, in metres
Vsc = Sheath voltage under fault conditions
Isc = Fault current in kA

Note:

For multicore cables, it can be bonded at both the ends and no derating in the cable
need to be considered.

In case of single core cable and bonded at both the ends, manufacturers
recommended derating factors need to be considered.

E) Type of cable installation

which includes

Ambient temperature/soil conditions

Type of Laying
Method of installation
Bonding of armours / screen (single end / double end)

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Various installation and laying methods will also derate the cable current carrying capacity.
These factors are given in the annexure.II ( As per manufacturers recommendations.)

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FIRE SURVIVAL CABLES

In case customer requirement is there for this type of cables following needs to be taken
care.
These cables are generally used for certain emergency /essential auxiliaries/critical areas
so as to ensure that these auxiliaries work satisfactorily under severe fire conditions.
Fire survival cables are recommended generally for the following areas :(As per CEA
guidelines)

DC emergency lub oil pump

DC hydrogen seal oil pump
DC emergency lighting for main building
DC cables from battery to charger and DC distribution board
Turbine lub oil pump (AOP)
Jacking oil pump
Emergency turbine trip by push button in control room
Boiler turbine:Generator intertrip which include interconnecting cables between :
-Boiler master fuel trip and turbine trip relays
-Generator trip relays and turbine trip relays
-Generator trip relays and generator breaker
-Generator trip relays and Generator field breaker
-Generator trip relays and unit auxiliary transformer

Exact areas to be adopted needs to be checked from project to project basis.These cables
are generally designed to meet the requirements of IEC 331 flame retardent
characteristics of 750 deg c for 3 hours.

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Cable Selection Procedure diagram

Input
(cable details, load details etc,.)

Check for Permissble

sheath voltage (for 1
core cable only)

Calculate Total continuous current = I

Apply various derating factors to arrive at :
1) Actual full load current (Ifl) = I X D1 X D2.......
2)Find minimum cable size (Afl) for Ifl from cable list
Calculate minimum cross section of
conductor based on Fault level (Asc)

Arrive at Preliminary cable size

= Max ( Afl , Asc)

Not available

Available
Calculate Voltage drop
(normal & starting)
Check availabilty of cable
size in project cable list
Is voltage drop within
Permissible limits?

Select Next higher size

NO

YES
Select the cable.
Find Max. permissible length.
YES

NO

Is Lmax > actual cable length

END

6.0
STANDARD
PROJECTS

RECOMMENDED

CABLES

SIZES

11 kV, XLPE, AL. conductor, (Armoured/Unarmoured)

3C X 150 SQ. mm
3C X 185 SQ. mm
3CX 240 SQ. mm

ADOPTED

FOR

ABB

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3C X 300 SQ. mm
1C X 400 SQ. mm
1C X 630 SQ. mm
6.6 kV, XLPE, AL. conductor, (Armoured/Unarmoured)
3C X 185 SQ. mm
3CX 240 SQ. mm
1CX 400 SQ. mm
3.3 kV ,XLPE AL conductor (Armoured/unarmoured)
3CX50 Sq mm
3CX95 Sqmm
3CX150 Sqmm
1CX240 Sqmm
1CX400 Sqmm
1CX500Sqmm
1.1 kV (LT power cables), PVC, AL. conductor, (Armoured/Unarmoured)
2C X 16 SQ. mm
2C X 35 SQ. mm
2C X 70 SQ. mm
2C X 120 SQ. mm
4C X 16 SQ mm
3.5C X 35 SQ. mm
3.5C X 70 SQ. mm
3.5C X 120 SQ. mm
3.5 X 185 SQ. mm
3.5C X 240 SQ. mm
1C X 400 SQ. mm
1C X 800 SQ. mm
1.1 kV (LT power cables), PVC, CU. conductor, (Armoured/Unarmoured)
4C X 4 SQ. mm
4C X 6 SQ. mm
1.1 kV (LT control cables), PVC, CU. conductor, (Armoured/Unarmoured)
3C X 1.5 SQ. mm
4C X 1.5 SQ. mm
7C X 1.5 SQ. mm
12C X 1.5 SQ. mm
19C X 1.5 SQ. mm
2C X 2.5 SQ. mm
3C X 2.5 SQ. mm
4C X 2.5 SQ. m m
5C X 2.5 SQ. mm
7C X 2.5 SQ. mm
12C X 2.5 SQ. mm

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