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

√3 x IRATED x (RCAB|900C Cosφ r + XCAB Sinφ r) x Lr

%VDROP = = -------------------------------------------------------------------------
V x n x 10

where,
IRATED = Rated Motor Current Amps
RCAB|900C = Resistance of Cable at 90 C 0
Ohms/KM
XCAB = Reactance of Cable Ohms/KM
Lr = Length of Cable (run) mts
V = Operating System Voltage Volts
n = No of parallel path/run
Cosφ r = Power Factor during running

2.2 Voltage Dip Calculation

√3 x IStart x (RCAB|900C Cosφ s + XCAB Sinφ s) x Ls

%VDIP = = ------------------------------------------------------------------------
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
V = Operating System Voltage Volts
n = No of parallel path/run
Cosφ s = Power Factor during start

Prep By : Abhijit Mandal

Page 1 of 8 I-MT OP PEP-EA2
2.3 Minimum Crossection of Cable

As per IEC - 60724 recomendation

I2t = K2S2

where

Qc(β + 20) θf - θi
K= ------------- x Loge 1 + ---------
ρ20 θi + β
where,
I = Short Circuit Current Amps
S = Cross Section of Cable sqmm
t = Duration of Short Circuit sec
O
θf = Final temp after Short Circuit C
O
θi = Initial temp before Short Circuit C
β = Reciprocal of temp co-efficient of resistance of current carrying component
K = Constant
Qc = Volumetric heat capacity of conductor material at 20OC J/OCmm3
ρ20 = Electrical resistivity of conductor material at 20OC Ωmm

3 Sample calculations for selection of Aluminium XLPE cable

3.1 System Parameters / Conductor Parameters 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 (From CTS / GS03)
O
Initial Temp of Cable Conductor = 90 C (From Manufacturer)
O
Final Temp of Cable Conductor = 250 C (From Manufacturer)
O
Recipro. of temp co-eff. of resistance = 228 C (From Manufacturer)
O
Resistivity of conductor Mat. at 20 C = 0.000028264 Ωmm (From Manufacturer)
O O 3
Vol. heat cap. of cond. Mat. at 20 C = 0.0025 J/ Cmm (From Manufacturer)
K = 94.6 (Calculated)
Required Min.Cross Section of Cable = 211 sqmm (Calculated)

Selected Cable 240 sqmm Al, XLPE

Prep By : Abhijit Mandal

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)
Running Conditions Remarks
Cable Route Length = 750 mts (From Layout)
Cable Size Selected = 240 sqmm (Selected)
Motor FL Current ( at 6.6 kV ) = 260 Amps @ 6.6 kV
Power Factor (Run) = 0.91 (Typical Data)

Cable Rating (at 40 0 C per run) = 395 A (Calculated)

Cable Ampacity (with DF = 0.65) = 257 A (Calculated)
No of Runs required = 2 No (Calculated)
Calculated Voltage Drop (Run) 0.48 % (Calculated)
Starting Conditions
Cable Route Length = 750 mts (From Layout)
Cable Size Selected = 240 sqmm (Selected)
Locked Rotor Current/Nominal Current = 1.5 times ( VFD Driven)
Motor Starting Current ( at 6.6 kV ) = 390 A (Calculated)
No of Runs required = 2 No (Calculated)
Calculated Voltage Drop (Start) 0.60 % (Calculated)

Table - 1 : Cable Data from Manufacturer

3C x 6.6/11 kV (UE) Al XLPE

Conductor Rcab at 90
Xcab at 90 degC STC (kA) Icab at 40 degC Derating
Size degC IcabD (A)
ohms/km for 1 Sec in air (A) Factor
(sqmm) 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 9 230 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

Prep By : Abhijit Mandal

Page 3 of 8 I-MT OP PEP-EA2
 Primary Dedusting ID Fan Motor (VFD Transformer to Motor via VFD)
Calculations & Selected Cable Parameters (from Table - 1)
Running Conditions Remarks
Cable Route Length = 200 mts (From Layout)
Cable Size Selected = 240 sqmm (Selected)
Motor FL Current ( at 4.16 kV ) = 415 Amps @ 4.16 kV
Power Factor (Run) = 0.91 (Typical Data)

Cable Rating (at 40 0 C per run) = 395 A (Calculated)

Cable Ampacity (with DF = 0.65) = 257 A (Calculated)
No of Runs required = 2 No (Calculated)
Calculated Voltage Drop (Run) 0.33 % (Calculated)
Starting Conditions
Cable Route Length = 200 mts (From Layout)
Cable Size Selected = 240 sqmm (Selected)
Locked Rotor Current/Nominal Current = 1.5 times ( VFD Driven)
Motor Starting Current ( at 4.16 kV ) = 623 A (Calculated)
No of Runs required = 2 No (Calculated)
Calculated Voltage Drop (Start) 0.40 % (Calculated)

Table - 1 : Cable Data from Manufacturer

3C x 6.6/11 kV (UE) Al XLPE

Conductor Rcab at 90
Xcab at 90 degC STC (kA) Icab at 40 degC Derating
Size degC IcabD (A)
ohms/km for 1 Sec in air (A) Factor
(sqmm) 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 9 230 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

Prep By : Abhijit Mandal

Page 4 of 8 I-MT OP PEP-EA2
 Secondary Dedusting ID Fan Motor (HTSS to VFD Transformer)
Calculations & Selected Cable Parameters (from Table - 1)
Running Conditions Remarks
Cable Route Length = 750 mts (From Layout)
Cable Size Selected = 240 sqmm (Selected)
Motor FL Current ( at 6.6 kV ) = 160 Amps @ 6.6 kV
Power Factor (Run) = 0.91 (Typical Data)

Cable Rating (at 40 0 C per run) = 395 A (Calculated)

Cable Ampacity (with DF = 0.65) = 257 A (Calculated)
No of Runs required = 1 No (Calculated)
Calculated Voltage Drop (Run) 0.60 % (Calculated)
Starting Conditions
Cable Route Length = 750 mts (From Layout)
Cable Size Selected = 240 sqmm (Selected)
Locked Rotor Current/Nominal Current = 1.5 times ( VFD Driven)
Motor Starting Current ( at 6.6 kV ) = 240 A (Calculated)
No of Runs required = 1 No (Calculated)
Calculated Voltage Drop (Start) 0.73 % (Calculated)

Table - 1 : Cable Data from Manufacturer

3C x 6.6/11 kV (UE) Al XLPE

Conductor Rcab at 90
Xcab at 90 degC STC (kA) Icab at 40 degC Derating
Size degC IcabD (A)
ohms/km for 1 Sec in air (A) Factor
(sqmm) 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 9 230 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

Prep By : Abhijit Mandal

Page 5 of 8 I-MT OP PEP-EA2
 Secondary Dedusting ID Fan Motor (VFD Transformer to Motor)
Calculations & Selected Cable Parameters (from Table - 1)
Running Conditions Remarks
Cable Route Length = 90 mts (From Layout)
Cable Size Selected = 240 sqmm (Selected)
Motor FL Current ( at 4.16 kV ) = 260 Amps @ 4.16 kV
Power Factor (Run) = 0.91 (Typical Data)

Cable Rating (at 40 0 C per run) = 395 A (Calculated)

Cable Ampacity (with DF = 0.65) = 257 A (Calculated)
No of Runs required = 2 No (Calculated)
Calculated Voltage Drop (Run) 0.09 % (Calculated)
Starting Conditions
Cable Route Length = 90 mts (From Layout)
Cable Size Selected = 240 sqmm (Selected)
Locked Rotor Current/Nominal Current = 1.5 times ( VFD Driven)
Motor Starting Current ( at 4.16 kV ) = 390 A (Calculated)
No of Runs required = 2 No (Calculated)
Calculated Voltage Drop (Start) 0.11 % (Calculated)

Table - 1 : Cable Data from Manufacturer

3C x 6.6/11 kV (UE) Al XLPE

Conductor Rcab at 90
Xcab at 90 degC STC (kA) Icab at 40 degC Derating
Size degC IcabD (A)
ohms/km for 1 Sec in air (A) Factor
(sqmm) 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 9 230 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

Prep By : Abhijit Mandal

Page 6 of 8 I-MT OP PEP-EA2
 Gas Holder (GRP) Booster Fan 300 kW
Calculations & Selected Cable Parameters (from Table - 1)
Running Conditions Remarks
Cable Route Length = 1000 mts (From Layout)
Cable Size Selected = 240 sqmm (Selected)
Motor FL Current ( at 6.6 kV ) = 29 Amps @ 6.6 kV
Power Factor (Run) = 0.91 (Typical Data)

Cable Rating (at 40 0 C per run) = 395 A (Calculated)

Cable Ampacity (with DF = 0.65) = 257 A (Calculated)
No of Runs required = 1 No (Calculated)
Calculated Voltage Drop (Run) 0.15 % (Calculated)
Starting Conditions
Cable Route Length = 1000 mts (From Layout)
Cable Size Selected = 240 sqmm (Selected)
Locked Rotor Current/Nominal Current = 6 times ( DOL)
Motor Starting Current ( at 6.6 kV ) = 175 A (Calculated)
No of Runs required = 1 No (Calculated)
Calculated Voltage Drop (Start) 0.71 % (Calculated)

Table - 1 : Cable Data from Manufacturer

3C x 6.6/11 kV (UE) Al XLPE

Conductor Rcab at 90
Xcab at 90 degC STC (kA) Icab at 40 degC Derating
Size degC IcabD (A)
ohms/km for 1 Sec in air (A) Factor
(sqmm) 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 9 230 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

Prep By : Abhijit Mandal

Page 7 of 8 I-MT OP PEP-EA2
 LCSS Dedusting 2000 kVA
Calculations & Selected Cable Parameters (from Table - 1)
Running Conditions Remarks
Cable Route Length = 750 mts (From Layout)
Cable Size Selected = 240 sqmm (Selected)
Trafo FL Current ( at 6.6 kV ) = 175 Amps @ 6.6 kV
Power Factor (Run) = 0.80 (Typical Data)

Cable Rating (at 40 0 C per run) = 395 A (Calculated)

Cable Ampacity (with DF = 0.65) = 257 A (Calculated)
No of Runs required = 1 No (Calculated)
Calculated Voltage Drop (Run) 0.66 % (Calculated)

Table - 1 : Cable Data from Manufacturer

3C x 6.6/11 kV (UE) Al XLPE

Conductor Rcab at 90
Xcab at 90 degC STC (kA) Icab at 40 degC Derating
Size degC IcabD (A)
ohms/km for 1 Sec in air (A) Factor
(sqmm) 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 9 230 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

Prep By : Abhijit Mandal

Page 8 of 8 I-MT OP PEP-EA2