Iocl Raipur 50kw Cabel Document

UJAAS ENERGY LIMITED
DESIGN BASICS OF CABLE SIZING

PROJECT : IOCL RAIPUR 50kW
FORMATE NO
DATE :- 09/01/2017
REV. DATE :- 00
Cable -Sizing Calculations
DESIGN & DEVELOPMENT OF IOCL RAIPUR 50kW SOLAR PV PROJECT
Document Number :- UEL-2016-IOCL-(RAIPUR)-ELE-001
Project Name :- IOCL RAIPUR 50kW SOLAR PV PROJECT
INDIAN OIL CORPORATION LIMITED

MARKETING DIVISION
Client Name :-

701, NRK BUSINESS PARK,
VIJAY NAGAR SQUARE, INDORE 452010
MADHYA PRADESH
EPC :-
PREPARED BY
SWAPNIL KOTWAL
REVIVED BY
R.G.
DOCUMENT TITLE :UJAAS DOC. NO. :SUBMISSION DATE:RIVISION NO. :-
APPROVED BY
COMMENTS :APPROVAL DATE :-
CABEL SIZING CALCULATION

UEL-2016-IOCL-(RAIPUR)-ELE-001
10/01/2017
00

FORMATE NO
09/01/2017
DATE
INDEX
Sr. No.
1
Purpose
Page No.
1
References
Basis of Calculation
Specification Requirment
Formula Used
Module Data Sheet
Solar DC Cable Data Sheet
AC Cabel Data Sheet
Solar DC Cabel Calculation 1C x 4 sqmm
10
Average Voltage Drop Calculation on DC Side
10
11
AC Cabel Voltage drop Calculation 3.5C x 35 sqmm

(INVERTER TO LT PANEL)
11
12
AC Cabel Voltage drop Calculation 3.5C x 35 sqmm

(LT PANEL TO CLIENT LT PANEL)
13
13
Conclusion
14

FORMATE NO
09/01/2017
DATE
1.0 Pourpose
This Document present a report on cable sizing calculation for the IOCL RAIPUR 50kW. The
design calculation aims at appropriate selection of cables considering the installation conditions,
ambient temperature, group de-rating & short circuit withstand. The cables sizes & the max
cabel length are calculated based on continuous current rating, ensuring voltage drop is within
permissible limits and checked for thermal short circuit capacity. Cables selections charts have
been prepared & are annexed for reference.
2.0 Reference
IS 694, IS 8130, IS 1554(Part-I&II), IS 5831, IS 3961, IS 3975
IEC 60227, ICE 60502,IEC 745
Waaree Module Datasheet
Polycab Cable Datasheet
3.0 Basis of Calculation
The System design parameters and the site ambient condition are listed are below.
Site Ambiant temperature = 40C
Selected cable short circuit at full load current
Running voltage drop does not exceed more than the permissible voltage drop of its
rated voltage
4.0 Specification Requirment
Tender Document- Tender No. 16MP43923/ Pg No 49/ 3.9 Cabling
o The DC Cable shall be 1.5 kV (DC) grade,heavy duty, compacted al/cu conductor, UV
resistant XLPE insulated, PVC inner-sheathed, galvanized steel wire/strip armoured,
fire/flame retardant low somke FRLS PVC outer sheathed. The cable shall in general
conform to IS 7098 (Part-I)
o The power cable shall be 1.1 kV grade, heavy duty, stranded copper couductor, UV
resistant XLPE insulated, PVC inner-sheathed, galvanized steel wire/strip armoured,
fire/flame retardant low somke FRLS PVC outer sheathed. The cable shall in general
conform to IS 1554 (Part-I & II) & other relevant standard.
o Control Cables : The cable shall be 1.1 kV grade, heavy duty, stranded cu conductor, PVC
type-A insulated, galvanised steel wire/strip armored,flame retardant low smoke (FRLS)
extruded PVC type ST-1 outer sheathed. The cables, shall, in genral conform to IS 1554
part-I & other relevent standard
o Technical Requirement:
a) Solar cables must have TUV certification
b) straight through joints should be avoided
c) The cables shall have an ambient operating temp range of -10C to +60C
d) Cable terminations shall be made with suitable cable lugs & sockets etc., crimped

e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
r)
FORMATE NO
09/01/2017
DATE
properly & passed through brass compression type cable gland at the entry & exit point
of the cubicles.
The cables shall be adequately insulated for the voltage required and shall be suitably
color coded for the requred service.
All the power cables shall be tested at the site as per the standard in front of EIC/
nominated officer present at the side. The cables shall also confirm to IEC 60189 for the
test and measuring methods & they should be UV protected. NO cable should be left
open.
Data sheet of individual cables sizes shall be submitted. Drum numbers and drum length
details shall be submitted with each consignment.
cables must be selected so as to minimize the risk of earth faults & faults & short ckt.
All exposed DC cables must be flexible single core & must satisfy the above criteria.
XLPE insulation shall be suitable for a continuous conductor temp of 90C & short Ckt
conductor temprature of 250C.
PVC insulation shall be suitable for a continuous conductor temp of 70C & short Ckt
conductor temprature of 160C.
All the cables of size 50 sqmm or higher shall be armoured, to fetch mechanical
protection of the sheath, insulation & conductor.
If the data transmission length is more than 100 m distance or as required, Optical fiber
cable shall be used.
Derating factor for various conditions of installation, including the folllowing, shall be
considered while selecting the cable size:
> Variation in ambiant temp for cables laid in air
> Grouping of cables
> Variation in ground temp & soil resistivity for buried cables
Following minimum marking shall be provided on the outer sheath
> Cable size & voltage grade
> Word 'FRSL' at every 5 mt
> Sequential marking of the length of cable in mt at every 1 mt
in addition, the printing shall be progressive, automatic, in line & marking shall be
legible & indelible
Cable are to be routed neatly in standard manner through GI parforated cables trays &
cable marker to be placed for further identification. For arrey wiring, suitable cable tray
or metal conduit with proper support shall be provided & fastened in accordance with
relevent standards, industry codes & Indian Electricity Grid code
Cable trays shall have standard width of 150 mm, 300 mm, & 600mm & standard lengths
of 2.5 meter. Thickness of mild steel sheets used for fabrication of cable trays & fitting
shall be minimum 2 mm. The thickness of side coupler plates shall be minimum 3 mm.
For the protection of unarmoured cables, suitable conduits shall be provided.
The switches/ckt breaker/conectors required should conform to IEC 60947 (Part- I,II,&III)
or IS 60947 (Part-I,II&III) EN 50521

FORMATE NO
09/01/2017
DATE
o Cabling on DC side of the system shall be as short as possible to minimize the voltage
drop in the wiring. Voltage drop on the DC side from array to the inverter should not be
more than 2%. In the light of this fact, the cross-sectional area of the cable should ba so
chosen such that the voltage drop introduced by it shall be within 2% of the system
voltage at peak power. Necessary design calculation in this regard duly certified by
Chartered Electrical Engineer shall be submitted to EIC for approval.
o For the AC cabling from inverter/PUC to existing feeder Bus, Armored PVC insulated
Cables shall be used. The sizing of cables shall be based on the maximum load flow
considering the voltage drop within the permissible limit of 3% & maximum short ckt
withstand capability. The design calculation for sizing of the cable cable duly certified
by chartered electrical engineer shall be submitted for EIC approval. The complete cable
shall be laid through trench or the tray (including preparation of trench and trays with
manpower & material, if required) & proper arrangement shall be made for end
termination, glanding and lugging with supply of material
o Overload protection is to be provided. Design overload capacity of 125% of continuous
rating for 10 sec has to be ensured. The principle aim for this protection is to reduce the
tolerable value before it reaches the PV or other subsystem components. The source
of over voltage can be lightning or any other atmospheric disturbance or internal system
disturbance.
5.0 Formula Used

A Voltage Drop of Cable Conductor in DC System
% VD =
IFL x L x R x 100
NxV
Where,
IFL = Full Load Current
L = length of the cable in Km
R = Resustance of the Cable in Ohm/Km (@20C)
N = Number of run
V = System Voltage/ String Voltage

FORMATE NO
09/01/2017
DATE
B Voltage Drop of Cable Conductor in 3 Phase System
% VD =
3 x I x (R COS + X SIN) x L x 100

NxV
Where,
I = Full load Current
R = Resistance of the Cable in Ohm/Km (@90C)
N = Number of run
COS = Full Load Power Factor
SIN = Full Load Power Factor
C Load Current Calculation
P = kVA = 3 x kV x I
P = VxI
Where,
P = Power in Watts
I = Load Current
V = Supply Voltage
COS = Power Factor
L = Length of the Cable
D Sizing on the Basis of Minimum X-SEC of Condutor
Cross Sectional Area
S=
I x t
k
Where,
S = Cross sectional Area
I = Value of Fault Current
t = Time of current in seconds
k = Factor Depending on the material of protective conductor

PROJECT : 1 MWp A&N PROJECT
FORMATE NO
09/01/2017
DATE
6 Module Data Sheet

PROJECT : 1 MWp A&N PROJECT
FORMATE NO
09/01/2017
DATE
7 POLYCAB SOLAR DC CABLE DATA SHEET

FORMATE NO
09/01/2017
DATE
8.0 POLYCAB AC CABLE DATA SHEET

FORMATE NO
09/01/2017
DATE
9.0 Solar DC Cabel Calculation 1C x 4 sqmm (ARRAY TO INVERTER)

Refer for Module Data Sheet Page No. 4
Sr. No.
1
2
3
4
5
PV Module Description
Maximum Power at STC (Pmax )
Optimum Operating Voltage (Vmp)
Optimum Operating Current (Imp)
Open circuit Voltage (Voc)
Short Circuit Current (Isc)
310
36.70
8.45
45.20
9.14
Value
W
V
A
V
A
Refer for Solar DC Cable Data Sheet Page No. 5

Sr. No.
1
2
3
4
5
PV Module Description
Cable Core Size
Maximun Resistance @ 20C
2 Adjacent Cable on Surface
Ambient Temp. Derating Factor @40C
Cable Grouping Derating Factor
Value
4 Sq mm
4.95 /Km
36 A
1
0.56
=
=
=
=
8.45
36.7
50
36
=
=
1
0.56
Overall Derating Factor
AxB
Overall Derating Factor
0.56
Full Load Current (Imp)/(IFL)

Optimum Operating Voltage (Vmp)
Length Of Cable
Continous current Rating of Cable
Cable Derating Factor
A Due to Ambient Temp. @40C
B Due to Cable Grouping
Derated Cable
Current
A
V
m
A
= Continous Current Rating of Cable X Overall Derating Factor
Derated cable Current

Calculation for No. of Run =
20.16 A
Actual Cable Current

Derated Cable Current
Calculation for Number of Run

Hence We have selected number of Run
=
=
0.42 Run
1 Run
8

FORMATE NO
09/01/2017
DATE
Precentage Voltage Drop of Cable Conductor in DC System
% VD =
IFL x L x R x 100
NxV
Where
Ifl =
L=
R=
N=
V=
Full Load Current

Length of Cable in Km
Resistance Of Cabel @20C
Number of Run
System Voltage
Calculation For System Voltage (V)
=
=
=
=
=
A
Km
/km
V
= No. of module in Series X Module Voltage
Number of Module in series

Module Votage (Vmp)
System Voltage (V)
% VD =
8.45
0.050
4.95
1
660.6
=
=
=
18 No's
36.7 V
660.6 V
8.45 x 4.95 x 0.17 x 100

1 x 660.6
% VD = 0.32 %
Voltage Drop is Within Permissible Limit i.e 1%
Area of Cross Section
S=
I x t
k
Where,
S=
I=
t=
k=
Crossectional Area Sq mm
Value of fault current in kA
Time of current flow in seconds
Factor depending on the metal conductor
=
=
=
0.020565
1
0.094
0.021 x 1
S=
0.094
S = 0.219 Sq mm

FORMATE NO
09/01/2017
DATE
10.0 Average Voltage Drop Calculation on DC Side
% VD =
IFL x L x R x 100
NxV
Where
Ifl =
L=
R=
N=
V=
Sr No.
1
2
3
4
5
Full Load Current

Length of Cable in Km
Resistance Of Cabel @20C
Number of Run
System Voltage
STRING
STRING 1
STRING 2
STRING 3
STRING 4
STRING 5
INVERTER
INV-1
INV-1
INV-1
INV-1
INV-1
LENGTH
0.05
0.04
0.03
0.04
0.05
=
=
=
=
=
%VD
0.317
0.253
0.190
0.253
0.317
Average Drop = 0.266
8.45
0.050
4.95
1
660.6
A
Km
/km
V
Voltage drop
2.09 V
1.67 V
1.25 V
1.67 V
2.09 V
1.76 V
Voltage drop on the DC side from array to the inverter should not be more than 2%
DC Voltage Drop is with in permissible limit.
0.32 %
Avg. DC Voltage Drop is with in permissible limit.
0.27 %
10

FORMATE NO
09/01/2017
DATE
11.0 AC Cabel Voltage drop Calculation 3.5C x 35 sqmm (INVERTER TO LT PANEL)

Inverter Rating in KW (P)
50 kW
Max AC current as per inverter manufacturer (IFL)
90 A
Length of the Cable
15 m
145 A
A. Due To Ambient Temperature Air (40C) for XLPE
B. Due To Ambient Temperature Ground (45C) for XLPE
0.87
C. Thermal Resistivity of soil (150C cm/W)
D. Depth of laying
E. Due to Grouping cables laid in Ground
0.87
145x0.87
126.15 A
Actual Current
Derated Current
Continous Current Rating of the selected cable in Ground

After Select Cable
Refer For AC Cable Catloge Pgae No.7
Derating Factor
Derating Factor = A x B x C x D x E
Derated cable current = Actual Current x Derating factor
Derated Current Rating =
Calculations for no. of Runs =
90
126.15
Required no. of Runs = 0.71

Hence we have selected no. of Run
Derated cable current for 1 No of run
Resistance of the selected Cable (R) in Ohm/Km (@ 90C)
1 Run
126.15 A
0.671 /km
11

Reactance of the selected Cable (X)
% VD =
% VD =
% Voltage drop =
/Km
0.08

NxV
Where,
N = Number of run
X = reactance of the cable in Ohm/Km
% VD =
FORMATE NO
09/01/2017
DATE
=
=
=
=
=
=
=
=
90.00
0.05
0.67
1.00
415.00
0.08
0.90
0.43
A
Km
/Km
Run
V
/Km
3 x 90 x {(0.671 x 0.9) + (0.08 x 0.43)} x 0.045 x 100

1 x 415
447.74
415
1.08
1.08 %
voltage drop is with in permissible limit.
Hence we selected 1.1kV 1R 3.5C 35sqmm XLPE Al Ar cable.
12

FORMATE NO
09/01/2017
DATE
12.0 AC Cabel Voltage drop Calculation 3.5C x 35 sqmm (LT PANEL TO CLIENT LT PANEL)
Inverter Rating in KW (P)
50 kW
Max AC current as per inverter manufacturer (IFL)
90 A
Length of the Cable
15 m
145 A
A. Due To Ambient Temperature Air (40C) for XLPE
B. Due To Ambient Temperature Ground (45C) for XLPE
0.87
C. Thermal Resistivity of soil (150C cm/W)
D. Depth of laying
E. Due to Grouping cables laid in Ground
0.87
145x0.87
126.15 A
Actual Current
Derated Current
Continous Current Rating of the selected cable in Ground

After Select Cable
Refer For AC Cable Catloge Pgae No.7
Derating Factor
Derating Factor = A x B x C x D x E
Derated cable current = Actual Current x Derating factor
Derated Current Rating =
Calculations for no. of Runs =
90
126.15
Required no. of Runs = 0.71

Hence we have selected no. of Run
Derated cable current for 1 No of run
Resistance of the selected Cable (R) in Ohm/Km (@ 90C)
1 Run
126.15 A
0.671 /km
13

Reactance of the selected Cable (X)
Where,
N = Number of run
X = reactance of the cable in Ohm/Km
/Km
0.08
=
=
=
=
=
=
=
=
90.00
0.02
0.67
1.00
415.00
0.08
0.90
0.43
A
Km
/Km
Run
V
/Km
3 x 90 x {(0.671 x 0.9) + (0.08 x 0.43)} x 0.015 x 100

1 x 415
149.25
415
% VD =
% Voltage drop =

NxV
% VD =
% VD =
FORMATE NO
09/01/2017
DATE
0.36
0.36 %
voltage drop is with in permissible limit.

Hence we selected 1.1kV 1R 3.5C 35sqmm XLPE Al Ar cable.
13.0 Conclusion
SUMMARY FOR AVERAGE VOLTAGE DROP % (OVER ALL COMPLETE SYSTEM)
1
2
3
4
ARRAY TO INVERTER
INVERTER TO LT PANLE
LT PANEL TO CLIENT LT PANEL
Total AC Voltage Drop
=
=
=
=
0.27
1.08
0.36
1.44
%
%
%
%
>> Voltage drop on the DC side from Array to the Inverter is not more than 2 %
>> Voltage drop on the AC side from Inverter to client LT Panel is not more than 3 %
14

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UJAAS ENERGY LIMITED

DESIGN BASICS OF CABLE SIZING

Cable -Sizing Calculations

DESIGN & DEVELOPMENT OF IOCL RAIPUR 50kW SOLAR PV PROJECT

Document Number :- UEL-2016-IOCL-(RAIPUR)-ELE-001

Project Name :- IOCL RAIPUR 50kW SOLAR PV PROJECT

INDIAN OIL CORPORATION LIMITED

UJAAS ENERGY LIMITED

DOCUMENT TITLE :UJAAS DOC. NO. :SUBMISSION DATE:RIVISION NO. :-

CABEL SIZING CALCULATION

UJAAS ENERGY LIMITED

Module Data Sheet

Solar DC Cable Data Sheet

AC Cabel Data Sheet

Solar DC Cabel Calculation 1C x 4 sqmm

Average Voltage Drop Calculation on DC Side

AC Cabel Voltage drop Calculation 3.5C x 35 sqmm

AC Cabel Voltage drop Calculation 3.5C x 35 sqmm

Document Number :- UEL-2016-IOCL-(RAIPUR)-ELE-001

UJAAS ENERGY LIMITED

UJAAS ENERGY LIMITED

Document Number :- UEL-2016-IOCL-(RAIPUR)-ELE-001

UJAAS ENERGY LIMITED

5.0 Formula Used

Document Number :- UEL-2016-IOCL-(RAIPUR)-ELE-001

UJAAS ENERGY LIMITED

B Voltage Drop of Cable Conductor in 3 Phase System

3 x I x (R COS + X SIN) x L x 100

Cross Sectional Area

UJAAS ENERGY LIMITED

6 Module Data Sheet

Document Number :- UEL-2016-IOCL-(RAIPUR)-ELE-001

UJAAS ENERGY LIMITED

7 POLYCAB SOLAR DC CABLE DATA SHEET

Document Number :- UEL-2016-IOCL-(RAIPUR)-ELE-001

UJAAS ENERGY LIMITED

8.0 POLYCAB AC CABLE DATA SHEET

Document Number :- UEL-2016-IOCL-(RAIPUR)-ELE-001

UJAAS ENERGY LIMITED

9.0 Solar DC Cabel Calculation 1C x 4 sqmm (ARRAY TO INVERTER)

Refer for Solar DC Cable Data Sheet Page No. 5

Overall Derating Factor

Overall Derating Factor

Full Load Current (Imp)/(IFL)

= Continous Current Rating of Cable X Overall Derating Factor

Derated cable Current

Actual Cable Current

Calculation for Number of Run

UJAAS ENERGY LIMITED

Precentage Voltage Drop of Cable Conductor in DC System

Full Load Current

Calculation For System Voltage (V)

= No. of module in Series X Module Voltage

Number of Module in series

8.45 x 4.95 x 0.17 x 100

UJAAS ENERGY LIMITED

10.0 Average Voltage Drop Calculation on DC Side

Full Load Current

Average Drop = 0.266

DC Voltage Drop is with in permissible limit.

Avg. DC Voltage Drop is with in permissible limit.

Document Number :- UEL-2016-IOCL-(RAIPUR)-ELE-001

UJAAS ENERGY LIMITED

11.0 AC Cabel Voltage drop Calculation 3.5C x 35 sqmm (INVERTER TO LT PANEL)