HT Cable Sizing Cal - For HT SWBD, Dist. Trafo. & HT Motor 27.07.10

HT CABLE SIZING CALCULATION
100TPH CLINKER GRINDING PLANT,

DAR Es - SALAAM.
M/s. WALCHANDNAGAR INDUSTRIES LTD., PUNE.
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CUSTOMER
M/s. MAWENI LIMESTONE LTD.
ELECTRICAL
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ARVEE ELECTRICALS & ENGINEERS PVT. LTD.,

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1.0
GENERAL
1.1
The intent of this document is to cover the basis and calculations for sizing of
6.6kV (UE), XLPE cables required for 6.6kV Main Switchboard, Distribution
Transformers, & HT Motors in the installations.
2.0
BASIS & ASSUMPTIONS

Following are the basis and assumptions made while sizing the HT cables.
2.1
6.6kV(UE) grade cables shall be Copper conductor with inner semi conducting layer
over conductor, XLPE insulated with semi conducting layer & copper tape over insulation
inner sheath, PVC extruded outer sheath, armoured cables.
2.2
The cables will be laid on cable trays and in single layer which will be shown in cable
layout drawing.
2.3
Design Ambient has been considered as 40C.
2.4
6.6kV (UE) Cable from 12.5MVA Power Transformer to 6.6kV Main Switchboard shall be
sized for carrying 26.3kA short circuit current for 1 second duration since numerical type
protective relays are provided in the system to isolate the faulty equipment within less
than 0.4 sec.
2.4
6.6kV (UE) Cable from 6.6kV Main Switchboard to Distribution Transformers shall be
sized for carrying 26.3kA short circuit current for 1 second duration since numerical type
protective relays are provided in the system to isolate the faulty equipment within less
than 0.6 sec
2.5
6.6kV (UE) Cable from 6.6kV Isolator Panel to HT Motor feeder shall be sized for
carrying short circuit current of 26.3kA for 0.2 second duration.
2.6
Starting current for 2200kW SR DOL motor is 3 times greater than rated current.
2.7
Following formula will be used for calculating receiving end terminal voltage during full
load conditions:
Page 1 of 12

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Vr Vs ( 3 I fl ( R Cos X Sin ) L ) (1000 N t )
Where,
Vr
= Voltage available at receiving end terminals during full load

Conditions.
Vs
= Nominal voltage of the system.
I fl
= Full Load current.
Cos
= Power factor during steady state conditions (Considered as 0.85 in

calculations).
= Resistance of power cable / km in .
= Reactance of power cable / km in .
= Route length of cable in meter. ( Route
Length
of
cables
considered are the estimated lengths with 10% margin)

Nt
2.8
= Number of Runs
Cable parameters such as resistance, reactance values etc. are taken from
Catalogues of Polycab make cables (Copy attached). These values for the cables
to be supplied actually will meet the values assumed in the calculations subject
to manufacturing tolerances as allowed in respective standards.
2.9
Calculation for Derating Factor
6.6kV (UE), XLPE, Copper conductor Cables for
Route of Power Trafo. to 6.6kV HT Switchboard;

2.9.
1
Derating factor for 40C
Ref. Annexure A: Polycab Cable

Catalogue - Table No. A (For Air &
Ambient Air temperatures.
Ground Temperature) on Page No. 3

2.9.
2
Cables
laid
inside
concrete
0.81
trench, on cable trays. The

cables spaced by one cable
Page 2 of 12
of 5.
Ref. Annexure A; Table No. A
on Page No. 4 of 5.

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diameter and trays are in tiers

spaced by 300mm.
No. of cable = 3 & No. of cable
2.9.
3
trays in tier = 3
Overall Derating Factor for 6.6
= 1 x 0.81
= 0.81
kV (UE) Cable installed

inside concrete trench on cable
trays.
2.10
Calculation for Derating Factor
6.6kV (UE), XLPE, Copper conductor Cables for
Overhead route;
2.10.
1
Derating factor for 40C
Ref. Annexure A: Polycab Cable

Catalogue - Table No. A (For Air &
Ambient Air temperatures.
Ground Temperature) on Page No. 3

2.9.2
Cables laid on cable trays
0.93
exposed to air, the cables
of 5.
Ref. Annexure A; Table No. A
on Page No. 4 of 5.
spaced by one cable diameter

& trays are in tiers cable
spaced by 300mm.
No. of cables = 2 & No. of cable
2.9.3
trays in tier = 6
Overall Derating Factor for 6.6
= 1 x 0.93
kV (UE) Cable installed on

cable
trays
on Cable
rack
exposed to air
Page 3 of 12
= 0.93

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3.0

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CABLE SIZING CALCULATION
3.1 Typical calculation of Cable sizing for 6.6kV (UE) Copper XLPE cable from 12.5MVA
Power Transformer to 6.6kV Main Switchboard.

3.1.1
Cable size confirmation for short circuit withstands capacity.

a) Maximum possible short circuit current on 6.6kV side : - 26.3kA for 1 sec.
b) Short circuit rating of selected cable (3C X 240 sq. mm) : - 34.3kA for 1 sec.
c) Duration for carrying short circuit current : - 1 sec.
Short circuit rating of selected cable is 34.3 kA for 1 sec. which is more than of possible
short circuit current of 26.3 kA for 1 sec.
Hence selected cable of size 3C X 240 sq. mm. is suitable for Short
Circuit Withstand Capacity.
3.1.2
Cable sizing based on Continuous Current Carrying Capacity.

a)
Full load current on 6.6kV side: - 1093.5A.
b)
Cable size considered
: - 3R x 3C x 240 Sq. mm. XLPE insulated Copper
conductor.
c)
Current rating of the cable under standard conditions of installation in trench

i.e. in Air : - 500A (Ref. Annexure A; Polycab Cable Catalogue, Table No.
24 of Page No. 5 of 5)
d)
As the Cables laid on cable trays exposed to air, the Derating factor
considered : - 0.81 (Ref 2.9.3 above)
e)
Derated capacity of cable : - 1215A as against requirement of 1093.5A.
Hence selected cable size of 3R x 3C x 240 Sq. mm. XLPE is suitable
Page 4 of 12

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for Continuous Current Carrying Capacity.

3.1.3
Cable sizing based on voltage drop during full load condition.

a)
Full load current on 11kV side: - 1093.5A.
b)
Route length of cable : - 190 meter
c)
Cable size considered : - 3R x 3C x 240 Sq. mm. XLPE insulated Copper

conductor.
d)
Voltage at receiving end terminals is given by following formula : Vr Vs ( 3 I fl ( R Cos X Sin ) L) (1000 N t )
e)
Resistance of cable at 90C : - 0.0965 / km (Ref: Annexure - A Polycab

Cable Catalogue, Table 1 of Page No. 1 of 5)
f)
Reactance of cable at 50 Hz. : - 0.085 / km (Ref: Annexure - A Polycab

Cable Catalogue, Table 6 of Page No. 2 of 5)
g)
Power Factor of system
(i.e. Cos): - 0.85 lagging. (Sin = 0. 526)
Now we have, Vr Vs ( 3 I fl ( R Cos X Sin ) L) (1000 N t )

Vr 6600 ( 3 1093.5 (0.0965 0.85 0.085 0.526) 190) (1000 3)
Vr 6600 (15.20)
Vr 6584.8 V
Now Percentage Voltage Drop, % VD (Vs Vr ) Vs 100
% V D (6600 6584.8) 6600 100
% VD 0.23 which is very negligible.
Hence 6.6kV (UE), 3R x 3C X 240 sq. mm. XLPE Copper conductor Cable is adequate for
Voltage Drop consideration.
Page 5 of 12

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3.2

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Typical calculation of Cable sizing for 6.6kV (UE) Copper XLPE cable from 6.6kV Main
Switchboard to 2000kVA Transformer.
3.2.1
Cable size confirmation for short circuit withstands capacity.

a)
Maximum possible short circuit current on 6.6kV side : - 26.3kA for 1 sec.
b) Short circuit rating of selected cable (3C X 185 sq. mm) : - 26.4kA for 1 sec.
c) Duration for carrying short circuit current for application: - 0.6 sec.
Selected short circuit current of cable is 26.4 kA for 1 sec. which is more than required
short circuit current of 26.3 kA for 0.6 sec.
Hence selected cable of size 3C X 185 sq. mm. is suitable for Short Circuit
Withstand Capacity.
3.2.2

a)
b)
Cable size considered
: - 3C x 185 Sq. mm. XLPE
insulated Copper
conductor.
c)
Current rating of the cable under standard conditions of installation in Air : 430A (Ref. Annexure A; Polycab Cable Catalogue, Table No. 24 on
Page No. 5 of 5)
d)
As the cables shall be laid on cable trays exposed to air, the derating factor
e)
Derated capacity of cable : - 399.9A as against requirement of 174.95A.
Hence selected cable size of 3C x 185 Sq. mm. XLPE is suitable for Continuous
Current Carrying Capacity.
Page 6 of 12

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Cable sizing based on voltage drop during full load condition.

a)
b)
Route length of cable : - 30 meter
c)
Cable
size considered
: - 3C x 185 Sq. mm. XLPE
insulated Copper
conductor.
d)
Voltage at receiving end terminals is given by following formula : Vr Vs ( 3 I fl ( R Cos X Sin ) L) (1000 N t )
e)
Resistance of cable at 90C : - 0.127 / km (Ref: Annexure - A Polycab

Cable Catalogue, Table 1 on Page No. 1 of 5)
f)
Reactance of cable at 50 Hz. : - 0.087 / km (Ref: Annexure - A Polycab

g)
Power Factor of system

Vr 6600 ( 3 174.95 (0.127 0.85 0.087 0.526) 30) (1000 1)
Vr 6600 (1.4)
Vr 6598.6 V
% V D (6600 6598.6) 6600 100
% V D 0.021 which is very negligible.
Hence 6.6kV (UE), 3C X 185 sq. mm. XLPE Cable is adequate for Voltage Drop
consideration.
Page 7 of 12

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3.3

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Typical calculation of Cable sizing for 6.6kV (UE) copper XLPE cable from 6.6kV
Isolator Panel to 6.6kV 2200kW Cement Mill Motor.
3.3.1 Cable size confirmation for Short Circuit Withstands Capacity.
a)
Maximum possible short circuit current on 6.6kV side : - 26.3kA for 1 sec.
b)
Short circuit rating of selected cable (3C X 185 sq. mm): - 26.4kA for 1 sec.
c)
Duration for carrying short circuit current : - 0.2 sec
Selected short circuit current of cable is 26.4 kA for 1 sec. which is more than required
short circuit current of 26.3 kA for 0.2 sec.
Hence selected cable of size 3C X 185 sq. mm. is suitable for Short Circuit
Withstand Capacity.
3.3.2

a)
b)
Cable size considered: - 3C x 185 Sq. mm. XLPE insulated Copper

conductor.
c)
Current rating of the cable under standard conditions of installation in air: 430A (Ref. Annexure A; Polycab Cable Catalogue, Table No. 24 on
Page. No. 5 of 5)
d)
As the cables shall be laid on cable trays exposed to air, the Derating factor
e)
Derated capacity of cable : - 399.9A as against requirement of 234.7A.
Hence selected cable size of 3C x 185 Sq. mm. XLPE is suitable for Continuous
Page 8 of 12

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Current Carrying capacity.
3.3.3
Cable sizing based on steady state Voltage Drop during full load condition.
a)
b)
Route length of cable: - 15 meter.
c)
Cable size considered: - 3C x 185 Sq. mm. XLPE insulated Copper

conductor.
d)
Voltage at receiving
end
terminals is given by following formula :-
Vr Vs ( 3 I fl ( R Cos X Sin ) L) (1000 N t )
e)
Resistance of cable at 90C : - 0.127 / km (Ref: Annexure A, Polycab

Cable Catalogue, Table No. 1 on Page No. 1 of 5)
f)
Reactance of cable at 50 Hz. : - 0.087 / km (Ref: Annexure A, Polycab

g)
Power Factor of motor

Vr 6600 ( 3 234.7 (0.127 0.86 0.087 0.510) 15) (1000 1)
Vr 6600 (0.939)
Vr 6599.061 V
% V D (6600 6599.061) 6600 100
Page 9 of 12

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Hence 6.6kV (UE), 3C X 185 sq. mm. XLPE Copper Conductor Cable is adequate for
Steady state Voltage Drop consideration.
3.3.4
Cable sizing based on Starting Voltage Drop during starting of the HT Motor.
a)
b)
Starting current of the motor:- 704.1A
c)
Route length of cable: - 15 meter.
d)
Cable
size considered: - 3C x 185 Sq. mm. XLPE
insulated Copper
conductor.
e)
Voltage at receiving
end
terminals is given by following formula :-
Vr Vs ( 3 I fl ( R Cos X Sin ) L) (1000 N t )
f)
Resistance of cable at 90C : - 0.127 / km (Ref: Annexure A, Polycab

Cable Catalogue, Table No. 1 on Page No. 1 of 5)
g)
Reactance of cable at 50 Hz. : - 0.087 / km (Ref: Annexure A, Polycab

h)
Power
Factor
of
system
at
starting
(i.e.
Cos):-
(Sin = 0. 95)
Vr 6600 ( 3 704.1 (0.127 0.3 0.087 0.95) 15) (1000 1)
Vr 6600 (2.22)
Vr 6597.78 V
Page 10 of 12
0.3
lagging.

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% V D (6600 6597.78) 6600 100

Hence 6.6kV (UE), 3C X 185 sq. mm. XLPE Copper conductor cable is adequate for
Starting Voltage Drop consideration.
4.0 CONCLUSION
4.1 The duration of short circuit withstand capacity of
6.6kV (UE), 3R x 3C X 240 sq.
mm. XLPE cable (34.3 kA for 1 sec) is more than the possible short circuit current
(i.e. 26.3kA for 1 sec.) in the system for HT switchboard.
6.6kV (UE), 3C X 185 sq. mm.
XLPE cable ( 26.4 for 1 sec) is more than the possible short circuit current (i.e.
26.3kA at 0.6 sec.) in the system for Dist. Trafo. Feeder.
6.6kV (UE), 3C X 185 sq. mm.
XLPE cable ( 26.4 kA for 1 sec) is more than the possible short circuit current (i.e.
26.3kA at 0.2 sec.) in the system for HT Motor feeder.
4.4 The
current carrying capacity of selected cables after deration is more than the
required current of the system.

4.5 Since the steady state voltage drop is much less than specified value of 5%, the cable
selection is correct from voltage drop point of view. The attainable steady state
voltage drop in cable is much less than the permissible voltage drop.
4.6 Since the starting voltage drop is much less than specified value of 15%, the cable
selection is correct from voltage drop point of view. The attainable starting
voltage drop in cable is much less than the permissible voltage drop.
Page 11 of 12

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The selected cables complies with all the requirements and hence the selection of
6.6kV (UE), 3C X 240 sq. mm. XLPE insulated Copper Cable for 6.6kV Main Switchboard &
6.6kV (UE), 3C X 185 sq. mm XLPE Insulated Copper Cable for Distribution Transformer &
HT Motor are adequate.
Page 12 of 12

HT Cable Sizing Cal - For HT SWBD, Dist. Trafo. & HT Motor 27.07.10

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HT CABLE SIZING CALCULATION

100TPH CLINKER GRINDING PLANT,

M/s. MAWENI LIMESTONE LTD.

ARVEE ELECTRICALS & ENGINEERS PVT. LTD.,

BASIS & ASSUMPTIONS

Design Ambient has been considered as 40C.

HT CABLE SIZING CALCULATION

M/s. MAWENI LIMESTONE LTD.

ARVEE ELECTRICALS & ENGINEERS PVT. LTD.,

Vr Vs ( 3 I fl ( R Cos X Sin ) L ) (1000 N t )

= Voltage available at receiving end terminals during full load

= Nominal voltage of the system.

= Full Load current.

= Power factor during steady state conditions (Considered as 0.85 in

= Resistance of power cable / km in .

= Reactance of power cable / km in .

= Route length of cable in meter. ( Route

considered are the estimated lengths with 10% margin)

Calculation for Derating Factor

6.6kV (UE), XLPE, Copper conductor Cables for

Route of Power Trafo. to 6.6kV HT Switchboard;

Derating factor for 40C

Ref. Annexure A: Polycab Cable

Ambient Air temperatures.

Ground Temperature) on Page No. 3

trench, on cable trays. The

HT CABLE SIZING CALCULATION

M/s. MAWENI LIMESTONE LTD.

ARVEE ELECTRICALS & ENGINEERS PVT. LTD.,

diameter and trays are in tiers

kV (UE) Cable installed

Calculation for Derating Factor

6.6kV (UE), XLPE, Copper conductor Cables for

Derating factor for 40C

Ref. Annexure A: Polycab Cable

Ambient Air temperatures.

Ground Temperature) on Page No. 3

Cables laid on cable trays

exposed to air, the cables

spaced by one cable diameter

kV (UE) Cable installed on

HT CABLE SIZING CALCULATION

M/s. MAWENI LIMESTONE LTD.

ARVEE ELECTRICALS & ENGINEERS PVT. LTD.,

CABLE SIZING CALCULATION

Power Transformer to 6.6kV Main Switchboard.

Cable size confirmation for short circuit withstands capacity.

Cable sizing based on Continuous Current Carrying Capacity.

Full load current on 6.6kV side: - 1093.5A.

Cable size considered

: - 3R x 3C x 240 Sq. mm. XLPE insulated Copper

Current rating of the cable under standard conditions of installation in trench

Derated capacity of cable : - 1215A as against requirement of 1093.5A.

Hence selected cable size of 3R x 3C x 240 Sq. mm. XLPE is suitable

HT CABLE SIZING CALCULATION

M/s. MAWENI LIMESTONE LTD.

for Continuous Current Carrying Capacity.

Cable sizing based on voltage drop during full load condition.

Full load current on 11kV side: - 1093.5A.

Route length of cable : - 190 meter

Cable size considered : - 3R x 3C x 240 Sq. mm. XLPE insulated Copper

Resistance of cable at 90C : - 0.0965 / km (Ref: Annexure - A Polycab

Reactance of cable at 50 Hz. : - 0.085 / km (Ref: Annexure - A Polycab