Cable Sizing PDF

Philosophy of Cable Sizing Methodology
1 General guideline for selection of Power Cables
The min size of the cable shall be 3 C x 185 sq.mm. of type A2XFY for XLPE insulated cables
as per IS : 7098 Part-II, Non-FRLS
Supply System : 6600 V , +6%, -9% / 50 Hz, +3%, -6%, 3-ph
Cable size for HT motors shall be selected on the basis of rated nameplate current, starting &
running voltage drop as per specification and short circuit capacity of the system. The cable size
shall be calculated based on the breaker opening time of 0.25 seconds
Short circuit capacity of 6.6 kV is 40kA .

AC motors of ratings in excess of 200KW upto 2000 KW shall be connected to 6.6 KV HT
power supply system.
2 Formulae used for calculation

2.1 Voltage Drop Calculation
%VDROP =
3 x IRATED x (RCAB|900C Cos r + XCAB Sin r) x Lr

= ------------------------------------------------------------------------V x n x 10
where,
IRATED
= Rated Motor Current
Amps
RCAB|900C
= Resistance of Cable at 90 C
Ohms/KM
XCAB
= Reactance of Cable
Ohms/KM
Lr
= Length of Cable (run)
mts
= Operating System Voltage
Volts
= No of parallel path/run
Cos r
= Power Factor during running
2.2 Voltage Dip Calculation
%VDIP =
3 x IStart x (RCAB|900C Cos s + XCAB Sin s) x Ls

= -----------------------------------------------------------------------V x n x 10
where,
IStart
= Motor Starting Current
Amps
RCAB|900C
= Resistance of Cable at 900C
Ohms/KM
XCAB
= Reactance of Cable
Ohms/KM
Ls
= Length of Cable (Start)
mts
= Operating System Voltage
Volts
= No of parallel path/run
Cos s
= Power Factor during start
Page 1 of 8
Prep By : Abhijit Mandal

I-MT OP PEP-EA2
2.3 Minimum Crossection of Cable
As per IEC - 60724 recomendation

I2t =
K2S2
where
K=
Qc( + 20)
------------20
x Loge 1 +
f - i
--------i +
where,
I
= Short Circuit Current
Amps
= Cross Section of Cable
sqmm
= Duration of Short Circuit
sec
= Final temp after Short Circuit
= Initial temp before Short Circuit
= Reciprocal of temp co-efficient of resistance of current carrying component
= Constant
Qc
= Volumetric heat capacity of conductor material at 20OC
J/OCmm3
20
= Electrical resistivity of conductor material at 20OC
mm
3 Sample calculations for selection of Aluminium XLPE cable

System Parameters / Conductor Parameters
3.1
Remarks
Supply Voltage
6.6
kV
(From CTS / GS03)
Fault Level
40
kA
(From CTS / GS03)
Fault Clearing Time
0.25
sec
(From CTS / GS03)
Conductor Material , Insulation
Al , XLPE
Initial Temp of Cable Conductor
90
(From Manufacturer)
250
(From Manufacturer)
228
(From Manufacturer)
0.000028264
Final Temp of Cable Conductor
Recipro. of temp co-eff. of resistance

O
Resistivity of conductor Mat. at 20 C

O
(From CTS / GS03)

O
(From Manufacturer)
mm
O
0.0025 J/ Cmm (From Manufacturer)
Vol. heat cap. of cond. Mat. at 20 C
94.6
Required Min.Cross Section of Cable
211
(Calculated)
sqmm
(Calculated)
Selected Cable 240 sqmm Al, XLPE
Page 2 of 8

I-MT OP PEP-EA2
Primary Dedusting ID Fan Motor (HTSS to VFD Transformer)

Calculations & Selected Cable Parameters (from Table - 1)
Remarks
Running Conditions
(From Layout)
Cable Route Length
750
mts
Cable Size Selected
240
sqmm
(Selected)
Amps
@ 6.6
Motor FL Current ( at 6.6 kV )
260
Power Factor (Run)
0.91
Cable Rating (at 40 0 C per run)
395
(Calculated)
Cable Ampacity (with DF = 0.65)
257
(Calculated)
No of Runs required
No
(Calculated)
0.48
(Calculated)
Calculated Voltage Drop (Run)
kV
(Typical Data)
Starting Conditions
(From Layout)
Cable Route Length
750
mts
Cable Size Selected
240
sqmm
(Selected)
Locked Rotor Current/Nominal Current
1.5
times
( VFD Driven)
Motor Starting Current ( at 6.6 kV )
390
(Calculated)
No of Runs required
No
(Calculated)
0.60
(Calculated)
Calculated Voltage Drop (Start)
Table - 1 : Cable Data from Manufacturer

3C x 6.6/11 kV (UE) Al XLPE
Conductor
Size
(sqmm)
Rcab at 90
degC
Ohms/km
35
1.1100
0.144
3.3
125
0.65
81
50
0.8200
0.137
4.7
150
0.65
98
70
0.5670
0.129
6.6
190
0.65
124
95
0.4100
0.123
230
0.65
150
120
0.3240
0.117
11.3
260
0.65
169
150
0.2640
0.114
14.2
295
0.65
192
185
0.2110
0.105
17.39
335
0.65
218
240
0.1600
0.106
22.6
395
0.65
257
300
0.1300
0.103
28.3
450
0.65
293
400
0.1000
0.099
37.7
520
0.65
338
Xcab at 90 degC STC (kA) Icab at 40 degC Derating

IcabD (A)
for 1 Sec
Factor
ohms/km
in air (A)
Page 3 of 8

I-MT OP PEP-EA2
Primary Dedusting ID Fan Motor (VFD Transformer to Motor via VFD)

Remarks
Running Conditions
Cable Route Length
Cable Size Selected
200
mts
240
sqmm
Amps
(From Layout)
(Selected)
415
Power Factor (Run)
0.91
395
(Calculated)
257
(Calculated)
No of Runs required
No
(Calculated)
0.33
(Calculated)
@ 4.16 kV
(Typical Data)
Starting Conditions
(From Layout)
Cable Route Length
200
mts
Cable Size Selected
240
sqmm
(Selected)
1.5
times
( VFD Driven)
623
(Calculated)
No of Runs required
No
(Calculated)
0.40
(Calculated)

Conductor
Size
(sqmm)
Rcab at 90
degC
Ohms/km
35
1.1100
0.144
3.3
125
0.65
81
50
0.8200
0.137
4.7
150
0.65
98
70
0.5670
0.129
6.6
190
0.65
124
95
0.4100
0.123
230
0.65
150
120
0.3240
0.117
11.3
260
0.65
169
150
0.2640
0.114
14.2
295
0.65
192
185
0.2110
0.105
17.39
335
0.65
218
240
0.1600
0.106
22.6
395
0.65
257
300
0.1300
0.103
28.3
450
0.65
293
400
0.1000
0.099
37.7
520
0.65
338

IcabD (A)
for 1 Sec
Factor
ohms/km
in air (A)
Page 4 of 8

I-MT OP PEP-EA2
Secondary Dedusting ID Fan Motor (HTSS to VFD Transformer)

Remarks
Running Conditions
Cable Route Length
750
mts
Cable Size Selected
240
sqmm
Amps
(From Layout)
(Selected)
160
Power Factor (Run)
0.91
395
(Calculated)
257
(Calculated)
No of Runs required
No
(Calculated)
0.60
(Calculated)
@ 6.6 kV
(Typical Data)
Starting Conditions
(From Layout)
Cable Route Length
750
mts
Cable Size Selected
240
sqmm
(Selected)
1.5
times
( VFD Driven)
240
(Calculated)
No of Runs required
No
(Calculated)
0.73
(Calculated)

Conductor
Size
(sqmm)
Rcab at 90
degC
Ohms/km
35
1.1100
0.144
3.3
125
0.65
81
50
0.8200
0.137
4.7
150
0.65
98
70
0.5670
0.129
6.6
190
0.65
124
95
0.4100
0.123
230
0.65
150
120
0.3240
0.117
11.3
260
0.65
169
150
0.2640
0.114
14.2
295
0.65
192
185
0.2110
0.105
17.39
335
0.65
218
240
0.1600
0.106
22.6
395
0.65
257
300
0.1300
0.103
28.3
450
0.65
293
400
0.1000
0.099
37.7
520
0.65
338

IcabD (A)
for 1 Sec
Factor
ohms/km
in air (A)
Page 5 of 8

I-MT OP PEP-EA2
Secondary Dedusting ID Fan Motor (VFD Transformer to Motor)

Remarks
Running Conditions
Cable Route Length
Cable Size Selected
90
mts
240
sqmm
Amps
(From Layout)
(Selected)
260
Power Factor (Run)
0.91
395
(Calculated)
257
(Calculated)
No of Runs required
No
(Calculated)
0.09
(Calculated)
@ 4.16 kV
(Typical Data)
Starting Conditions
(From Layout)
Cable Route Length
90
mts
Cable Size Selected
240
sqmm
(Selected)
1.5
times
( VFD Driven)
390
(Calculated)
No of Runs required
No
(Calculated)
0.11
(Calculated)

Conductor
Size
(sqmm)
Rcab at 90
degC
Ohms/km
35
1.1100
0.144
3.3
125
0.65
81
50
0.8200
0.137
4.7
150
0.65
98
70
0.5670
0.129
6.6
190
0.65
124
95
0.4100
0.123
230
0.65
150
120
0.3240
0.117
11.3
260
0.65
169
150
0.2640
0.114
14.2
295
0.65
192
185
0.2110
0.105
17.39
335
0.65
218
240
0.1600
0.106
22.6
395
0.65
257
300
0.1300
0.103
28.3
450
0.65
293
400
0.1000
0.099
37.7
520
0.65
338

IcabD (A)
for 1 Sec
Factor
ohms/km
in air (A)
Page 6 of 8

I-MT OP PEP-EA2
Gas Holder (GRP) Booster Fan 300 kW

Remarks
Running Conditions
Cable Route Length
Cable Size Selected

Power Factor (Run)
1000
mts
(From Layout)
(Selected)
240
sqmm
29
Amps
0.91
395
(Calculated)
257
(Calculated)
No of Runs required
No
(Calculated)
0.15
(Calculated)
@ 6.6 kV
(Typical Data)
Starting Conditions
(From Layout)
Cable Route Length
1000
mts
Cable Size Selected
240
sqmm
(Selected)
times
( DOL)
175
No of Runs required
(Calculated)
No
(Calculated)
0.71
(Calculated)

Conductor
Size
(sqmm)
Rcab at 90
degC
Ohms/km
35
1.1100
0.144
3.3
125
0.65
81
50
0.8200
0.137
4.7
150
0.65
98
70
0.5670
0.129
6.6
190
0.65
124
95
0.4100
0.123
230
0.65
150
120
0.3240
0.117
11.3
260
0.65
169
150
0.2640
0.114
14.2
295
0.65
192
185
0.2110
0.105
17.39
335
0.65
218
240
0.1600
0.106
22.6
395
0.65
257
300
0.1300
0.103
28.3
450
0.65
293
400
0.1000
0.099
37.7
520
0.65
338

IcabD (A)
for 1 Sec
Factor
ohms/km
in air (A)
Page 7 of 8

I-MT OP PEP-EA2
LCSS Dedusting 2000 kVA

Remarks
Running Conditions
Cable Route Length
Cable Size Selected
750
mts
240
sqmm
Amps
(From Layout)
(Selected)
Trafo FL Current ( at 6.6 kV )
175
Power Factor (Run)
0.80
395
(Calculated)
257
(Calculated)
No of Runs required
No
(Calculated)
0.66
(Calculated)
@ 6.6 kV
(Typical Data)

Conductor
Size
(sqmm)
Rcab at 90
degC
Ohms/km
35
1.1100
0.144
3.3
125
0.65
81
50
0.8200
0.137
4.7
150
0.65
98
70
0.5670
0.129
6.6
190
0.65
124
95
0.4100
0.123
230
0.65
150
120
0.3240
0.117
11.3
260
0.65
169
150
0.2640
0.114
14.2
295
0.65
192
185
0.2110
0.105
17.39
335
0.65
218
240
0.1600
0.106
22.6
395
0.65
257
300
0.1300
0.103
28.3
450
0.65
293
400
0.1000
0.099
37.7
520
0.65
338

IcabD (A)
for 1 Sec
Factor
ohms/km
in air (A)
Page 8 of 8

I-MT OP PEP-EA2

Cable Sizing PDF

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Philosophy of Cable Sizing Methodology

1 General guideline for selection of Power Cables

Supply System : 6600 V , +6%, -9% / 50 Hz, +3%, -6%, 3-ph

Short circuit capacity of 6.6 kV is 40kA .

2 Formulae used for calculation

3 x IRATED x (RCAB|900C Cos r + XCAB Sin r) x Lr

= Rated Motor Current

= Length of Cable (run)

= Operating System Voltage

= Power Factor during running

2.2 Voltage Dip Calculation

3 x IStart x (RCAB|900C Cos s + XCAB Sin s) x Ls

= Motor Starting Current

= Resistance of Cable at 900C

= Length of Cable (Start)

= Operating System Voltage

= Power Factor during start

Prep By : Abhijit Mandal

2.3 Minimum Crossection of Cable

As per IEC - 60724 recomendation

= Short Circuit Current

= Cross Section of Cable

= Duration of Short Circuit

= Final temp after Short Circuit

= Initial temp before Short Circuit

= Reciprocal of temp co-efficient of resistance of current carrying component

= Volumetric heat capacity of conductor material at 20OC

= Electrical resistivity of conductor material at 20OC

3 Sample calculations for selection of Aluminium XLPE cable

(From CTS / GS03)

(From CTS / GS03)

Fault Clearing Time

(From CTS / GS03)

Conductor Material , Insulation

Initial Temp of Cable Conductor

Final Temp of Cable Conductor

Recipro. of temp co-eff. of resistance

Resistivity of conductor Mat. at 20 C

(From CTS / GS03)

0.0025 J/ Cmm (From Manufacturer)

Vol. heat cap. of cond. Mat. at 20 C

Required Min.Cross Section of Cable

Selected Cable 240 sqmm Al, XLPE

Prep By : Abhijit Mandal

Primary Dedusting ID Fan Motor (HTSS to VFD Transformer)

Cable Route Length

Cable Size Selected

Motor FL Current ( at 6.6 kV )

Power Factor (Run)

Cable Rating (at 40 0 C per run)

Cable Ampacity (with DF = 0.65)

Calculated Voltage Drop (Run)

Cable Route Length

Cable Size Selected

Locked Rotor Current/Nominal Current

Motor Starting Current ( at 6.6 kV )

Calculated Voltage Drop (Start)

Table - 1 : Cable Data from Manufacturer

Xcab at 90 degC STC (kA) Icab at 40 degC Derating

Prep By : Abhijit Mandal

Primary Dedusting ID Fan Motor (VFD Transformer to Motor via VFD)

Cable Size Selected