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DESIGN MANUAL ELECTRICAL DEPARTMENT HIGH VOLTAGE CABLE SIZING

No. DCB08-05 Date: MAY 1998 Rev. : 0

INTRODUCTION : High Voltage Cables are sized based on the short-circuit withstand capacity for the specified fault clearing time, continuous current carrying capacity suitably derated depending on the conditions of installation and permissible voltage drop in the cable. Short circuit withstand capacity for power feeders shall be equal to the fault level at switchgear bus. For motor feeders, short circuit withstand capacity shall be that of the fault level at the terminals of the motor.

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No. DCB08-05 Date: MAY 1998 Rev. : 0

Fault withstand time can be taken as shown below :

Cables protected by circuit breakers shall be rated for short circuit duty. Cables protected by HRC Fuses, may not be sized for short circuit duty. However a minimum time t of 0.02 sec. is considered as safe & indicated as a minimum requirement.

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No. DCB08-05 Date: MAY 1998 Rev. : 0

STANDARD / REFERENCES : 1. 2. Cable corporation of India Ltd. Catalogue for Tropothen-X cables. (March 1994) Beemans Handbook.

3.0

SAMPLE CALCULATION : INPUT System fault level = Fault level at motor terminal = Fault clearing time = 26.2 kA at 6.6 kV 10 kA at 6.6 kV 0.5 sec for power feeder and 0.2 sec for motor & capacitor feeder.

For motor feeders Maximum voltage drop :- 5% running, 15% starting condition. Cable catalog for resistance and reactances. Multicore lables are laid on cables tray in air at ambient temperature of 40C. There are 3 tier cable trays with 6 cables having one diameter spacing between each other. FORMULA USED S = , where S t K is the is the is the is the minimum cross section area of the conductor in mm. fault current in Amperes (rms) fault withstand time in secs. constant. Amp/mm2

For XLPE Cables KCopper KAluminimum = = 143 94

For PVC Cables KCopper KAluminimum = 112 = 75

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No. DCB08-05 Date: MAY 1998 Rev. : 0

Voltage drop = (R Cos + X Sin) where, R X Cos = = = = = is the is the is the is the is the load current in amperes length of cable in kilometers resistance of cable in /km reactance of cable in /km power factor of the running load.

The resistance & reactor values are at the Maximum conductor temperature of XLPE cable 90C and PVC cables 70C. CABLE DERATION FACTOR : Cables ampacity has to be derated with respect to conditions of installation. Rating factors to be considered are : a) b) c) d) Variation in ambient air temperature for cables laid in air / ground temperature for cables laid underground. Cable laying arrangement. Depth of laying for cables laid direct in ground. Variation in thermal resistivity of soil. Derating factor = Product of Rating factors. Refer Appendix-I for Rating factor tables of XLPE cable. NOTE : A typical calculation of XLPE cable is made. In case of PVC cables the vendors catalogues for various derating factors shall be used.

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No. DCB08-05 Date: MAY 1998 Rev. : 0

CALCULATION

M in i m uo m s s Cs re n c at iroe a o f C o n d uf o c rt oXr L a P bE leC w it h = A l u m i nc iou nmd uf c o tr o=tr 0 . 5 s e c M i n i m uo m s s Cs re n c at iroe a o f C o n d uf o c rt oXr L a P bE l eC w it h = A l u m inc iou nmd uf c o tr o=tr 0 . 2 s e c

= = 197.08 mm2

= = 47.5 mm2

Standard conductor size to meet the minimum cross section area is 240 sq. mm. having an ampacity of 390A in air for t = 0.5 sec and 26.2 kA at 6.6 kV and 50 sq. mm having an ampacity of 145A in air for t = 0.2 sec and 10 kA at 6.6 kV. Derating factor = = = Product of rating factor Rating factor for variation in ambient temperature x Rating factor for laying conditions 1 x 0.89 = 0.89

Therefore, derated ampacity of cable is 390A x 0.89 = 347.1 Amperes for 3 x 240 sq. mm and 145A x 0.89 = 129.05 Amperes for 3 x 50 sq. mm. CASE - 1 : 200 A power feeder with cable run of 200 meters and power factor 0.9. 1 No. 3 x 240 sq. mm. is sufficient considering minimum cross section area and ampacity. Cable Resistance R = Cable Reactance X = Voltage drop = = 0.161 / km 0.093 / km. X 200 x 0.2 (0.161 x 0.9 + 0.093 x 0.435) 12.84 Volts

% Voltage drop = 0.19% which is within limits 1 No. 3 X 240 sq. mm. cable considered is safe.

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No. DCB08-05 Date: MAY 1998 Rev. : 0

CASE - 2 : 430 kW motor with a power factor of 0.9 at full load and 0.3 at starting. Cable run is for 200 meters. Full load current = Amperes 1 No. 3 x 50 sq. mm is sufficient considering minimum cross section area and ampacity. Locked rotor current Cable Resistance R Cable Reactance X Starting voltage drop = = = = = = 6 times full load current 6 x 41.7 = 250.2 Amperes 0.822 / km 0.117 / km x 250.2 x 0.2 [0.822 x 0.3 + 0.117 x 0.95] 31.0 V x 100 = 0.46% which is within limits x 41.7 x 0.2 [0.822 x 0.9 + 0.117 x 0.435] 11.42 V x 100 = 0.17% which is within limits

% Voltage drop starting = Full load voltage drop = =

% Voltage drop full load =

1 No. 3 X 50 sq. mm. Cable considered is safe. CASE - 3 : 300 kVAR capacitor feeder with cable run of 50 meters and 0.9 power factor Current = = 26.24 Amperes Considering the continuous capacity of the capacitors at 135%, the cable shall be sized to carry charging in rush current of 1.35 times rated capacitor current = 1.35 x 26.24A = 35.4 Amperes.

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No. DCB08-05 Date: MAY 1998 Rev. : 0

1 No. 3 x 240 sq. mm is sufficient considering minimum cross section area and ampacity. Voltage drop = = x 35.4 x 0.05 [0.161 x 0.9 + 0.093 x 0.435] 0.56 V x 100 = 0.01% which is within limits

% Voltage drop starting =

1 No. 3 X 240 sq. mm. Cable considered is adequate. CONCLUSION : 3 X 240 sq. mm. XLPE Aluminium cable has been selected for 200 A power feeder and 300 KVAR capacitor feeder. 3 x 50 sq. mm XLPE Aluminum cable has been selected for 430 kw motor feeder.

DESIGN MANUAL ELECTRICAL DEPARTMENT HIGH VOLTAGE CABLE SIZING Page: 8 of 11 APPENDIX - I Rating factors for variation in ambient air temperature Air Temperautre - C Rating Conductor Factors Temp. 90C 20 1.18 25 1.14 30 1.10 35 1.05 40 1.00 45 0.95 50 0.89

No. DCB08-05 Date: MAY 1998 Rev. : 0

55 0.84

60 0.78

Rating factors for variation in ground temperature : Ground C Rating Factors Temperautre Conductor Temp. 90C 15 1.12 20 1.08 25 1.04 30 1.00 35 0.96 40 0.91 45 0.87 50 0.82

Rating factors for multicore cables laid on open racks in air :

No of racks 1 2 3 6

No of cables 1 2 1.00 0.98 1.00 0.95 1.00 0.94 1.00 0.93

per rack 3 6 0.96 0.93 0.93 0.90 0.92 0.89 0.90 0.87

9 0.92 0.89 0.88 0.86

No of racks 1 2 3 6

No of 1 1.00 1.00 1.00 1.00

cables 2 0.84 0.80 0.78 0.76

per rack 3 6 0.80 0.75 0.76 0.71 0.74 0.70 0.72 0.68

9 0.73 0.69 0.68 0.66

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No. DCB08-05 Date: MAY 1998 Rev. : 0

Rating factors for single core cable in trefoil circuits laid on open racks in air

No of racks 1 2 3 6

No of circuits per rack 1 2 1.00 0.98 1.00 0.95 1.00 0.94 1.00 0.93

3 0.96 0.93 0.92 0.90

Rating factors for grouping of multicore cables laid direct in ground, in horizontal formation : SPACING No. of cables in group 2 3 4 0.79 0.82 0.86 0.69 0.72 0.76 0.62 0.66 0.72

6 0.54 0.59 0.65

8 0.50 0.54 0.62

10 0.46 0.51 0.59

Cables touching 15 cm 30 cm

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No. DCB08-05 Date: MAY 1998 Rev. : 0

Rating factors for grouping of multicore cables laid direct in ground in tier formation : Formation of cables Spacing

Cables touching 15 cm 30 cm

0.60 0.64 0.69

0.51 0.55 0.60

0.43 0.46 0.50

Rating factors for grouping of single core cable laid in trefoil circuits laid direct in ground in horizontal formation : Spacing 2 Cables touching 15 cm 30 cm 0.78 0.81 0.85 3 0.68 0.71 0.76 No. of circuits in group 4 6 8 0.61 0.65 0.71 0.53 0.57 0.64 0.48 0.53 0.60 10 0.45 0.50 0.58

Rating factors for depth of laying for Cables laid direct in the ground : Depth of laying (cm) 6.6kV & 11kV 22kV & 33kV 90 1.00 -105 0.99 1.00 120 0.98 0.99 150 0.96 0.97 180 or more 0.95 0.96

Rating factors for variation in thermal resistivity of soil : Rating factors for value of Thermal Resistivity of Soil in C cm/Watt 100 120 150 200 250 300 1.20 1.11 1.00 0.89 0.80 0.73

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No. DCB08-05 Date: MAY 1998 Rev. : 0

Arrangement for which reduction in current rating is not required : For cables sizes upto 70 sq. mm. conductor section, reduction in rating for grouping for cable in air need not be applied, provided, the circuits are run with a clearance of at least 75 mm and installed in a horizontal plane, when number of circuits are more than three. For cables above 70 sq. mm. conductor section, no reduction in rating be applied provided the circuits are run with a clearance of at least 150 mm, and installed in a horizontal plane as and when the number of circuits exceed four.

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