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Practical and Theoretical Investigation of Current Carrying Capacity (Ampacity)

of Underground Cables

Article · January 2013

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Advances in Electrical Engineering Systems (AEES) 163
Vol. 1, No. 3, 2012, ISSN 2167-633X
Copyright © World Science Publisher, United States
www.worldsciencepublisher.org

Practical and Theoretical Investigation of Current Carrying

Capacity (Ampacity) of Underground Cables
1
Adel El-Faraskoury, 2Sherif Ghoneim, 2Ali Kasem Alaboudy, 2Ragab Salem, 3Sayed A. Ward
1
Extra High Voltage Research Center, Egyptian Electricity Holding Company, Egypt, a.elfaraskoury@yahoo.com
2
Faculty of Industrial Education, Suez University, Suez Campus, Suez,
Egypt, ghoneim_sherif2003@yahoo.com; ali_hkasem@yahoo.com
3
Faculty of Engineering, Benha University, Shoubra, Cairo, Egypt, drsayedw@yahoo.com

Abstract – In urban areas, underground cables are commonly used for bulk power transmission. The utilization of
electricity in factories, domestic premises and other locations is typically performed by cables as they present the most
practical means of conveying electrical power to equipment, tools and other different applications. Estimation of cable
current carrying capacity (ampacity) gains higher potential in recent times due to the continuous increase of energy
utilization in modern electric power systems. This paper presents a theoretical study based on relevant IEC standards to
calculate the ampacity of underground cables under steady state conditions. The ampacity formula stated in IEC standards
are coded using Matlab software. Further, an untraditional experimental ampacity test of a 38/66 kV- XLPE/CU- 1 X 630
mm2 cable sample is performed in the extra high voltage research center. This paper proposes a new approach that uses the
complementary laboratory measurements in cable ampacity data preparation. The modified approach gives more accurate
estimation of cable parameters. The level of improvement is assessed through comparisons with the traditional ampacity
calculation techniques. Main factors that affect cable ampacity, such as the insulation condition, soil thermal resistivity,
bonding type, and depth of laying are examined. Based on paper results, cable ampacity is greatly affected by the installation
conditions and material properties.

Keywords – Underground cable; Cable ampacity; Soil thermal resistivity; Bonding type; Depth of laying

1. Introduction
Compared with transient temperature rises caused by
sudden application of bulk loads, the calculation of the
temperature rise of cable systems under steady state
conditions, which includes the effect of operation under a
repetitive load cycle, is relatively simple. Steady state cable
ampacity involves only the application of the thermal
equivalents of Ohm’s and Kirchoff’s laws to a relatively
simple thermal circuit. This analogy circuit usually has a
number of parallel paths with heat flows entering at several
points. However, heat flows and thermal resistances
involved should be carefully addressed. Differing methods
are sometimes used by various engineers. In general, all
thermal resistances are developed according the conductor
heat flowing through them. The ampacity or current
carrying capacity of a cable is defined as the maximum
current which the cable can carry continuously without the
temperature at any point in the insulation exceeding the
limits specified for the respectively material. The ampacity
depends upon the rate of heat generation within the cable as
well as the rate of heat dissipation from the cable to the
surroundings. In the case of underground cable systems, it is
convenient to utilize an effective thermal resistance for the
earth portion of the thermal circuit which includes the effect
of the loading cycle and the mutual heating effect of the
other cable of the system. Ampacity of an underground
cable system is determined by the capacity of the
installation to extract heat from the cable and dissipate it in
the surrounding soil and atmosphere. The maximum
operating temperature of a cable is a function of the
insulation damage experienced as a consequence of high
operating temperatures. Based on the duration of the current
circulating in the conductors, the cable insulation can
withstand different temperature values [1]. There are three
standardized ampacity ratings: steady state, transient (or
emergency) and short-circuit. This paper focuses only on
cable steady state ampacity ratings. Theoretical and
experimental investigation of cable ampacity is conducted.
2. Cable ampacity calculation
Adel El-Faraskoury, et al., AEES, Vol. 1, No. 3, pp. 163-169, 2012
The maximum temperature that the cable insulation can
be endured for long term determines its ampacity. The long
term and short term allowable maximum temperatures
ensure that the cable can operate safely, reliably and
economically. If the operating temperature exceeds certain
limit, the insulation aging becomes faster and thus shortens
the cable’s life span. In addition, the electrical and
mechanical properties, and thermal behavior must be
considered in choosing cable to ensure that the heat is not
exceeding the limited value while the transmission
capability is satisfied. The thermal behaviour of the
cables in underground lines during regimes of normal
load or under emergency not only depends on the
previous knowledge of the constructive characteristics
of the cable and the load curve that submitted, but
also of the way conditions where it is installed. Thus
other factors will have to be known as: amount of
loaded conductors, geometric configuration between
the cable, type of grounding of the metallic shields of
Figure 1. Electrical equivalent of thermal circuit
From Figure (1) we can compute Δ t as follows:
 
∆t = Wc + Wd T1 (Wc + Wd + Ws )T2 +
1
 2  (1)
(Wc + Wd + Wa )(T 2 + T 4)
To derive an expression from where the ampacity can
be computed directly, the heat sources (electrical losses)
W's are expressed as proportion of the conductor losses
(W c ). The conductor losses are computed using the ac
resistance and the current. Thus, by substituting the
following expressions:
Ws = λ1Wc , Wa = λ1Wc , Wc = Rac I 2 (2)
In (1) and re-arranging we have:
∆t − W4 [0.5T1 + n(T2 + T3 + T4 )]
I=
RT1 + nR(1 + λ1 + λ 2 )[T3 + T4 ]
(3)
164
the cable, thermal characteristics of the materials
around of the cable (soil, ducts, concrete, "backfill",
etc), effect of the typical variation of the environment
(humidity and temperature in the land) and other
interferences caused for external sources of heat. The
maximum temperature that XLPE insulation enduring is 90
ºC, so when the cable core come to this temperature, the
current in the cable core is considered cable ampacity. IEC
60287 support a method for calculation the cable ampacity
of 100% load current, which is a common method used in
all over the world. To find the ampacity, we first note that
the potential of every node in the circuit analogizes the
temperature of the regions between the layers. Thus, the
potential difference between the terminals of the circuits
and the innermost current source represents the temperature
rise of the core of the cable with respect to the ambient
temperature. Therefore the temperature of the cable's core is
the ambient temperature plus Δ t; Figure 1 shows thermal
electrical equivalent.
From expression (3) one can compute the ampacity of a
cable by calculating the thermal resistances T, the loss
factors λ and the ac resistance R of the core of the cable.
The loss factors λ take into account eddy losses induced and
circulating currents, while R considers the temperature
dependency of the resistance [2,3,4,5]. T 1, T 2 is related with
insulation material and the cable’s physical dimension.
Besides the cable’s construction, T 4 also has relationship
with the soil thermal resistance coefficient, namely the
earth’s property and moisture content. If the three cables
contact with each other, the interrelationship of these cables
also should be considered in. The loss factor λ1, λ 2 , relate
to the resistance of sheath and armour. The resistance is the
function of temperature. In IEC standard, the temperature of
sheath and armour are estimated by the maximum
temperature insulation endured, but in effect, they also have
some relationship with ambient temperature and the current
in the cable core. So the cable ampacity calculated by IEC
standard has some errors. An iterative method for
calculation ampacity is provided in this paper based on
precise calculation of circulating current in cable sheath.
Firstly, the cable core is given an initial current, and the
Adel El-Faraskoury, et al., AEES, Vol. 1, No. 3, pp. 163-169, 2012
initial temperatures of the core and sheath are also given.
Secondly, iterative calculate their temperatures under this
current. Thirdly, change the core current continually based
on the temperature difference between the core and its
allowable maximum temperature, until this difference is
smaller than the given error [6]. When the conductor is
energized, heat is generated within the cable. This heat is
generated due to the I2R losses of the conductor, the
dielectric losses in the insulation and losses in the metallic
component of the cable. The ampacity of the cable is
dependent on the way this heat is transmitted to the cable
surface and ultimately dissipated to the surrounding. The
thermal resistances control heat dissipation from the
conductor. Thus the efficiency of heat dissipation is
dependent upon the various thermal resistances of the cable
material and the external backfill and soil plus the ambient
temperature around the cable. If the cable is able to
dissipate more heat, the cable can carry more current.
In the Neher-McGrath method [1], the thermal resistances
are either computed from basic principles or from
heuristics. One can appreciate, from Figure 3, that some of
the internal layers of a cable can be considered as tubular
geometries. The following expression is used for the
computation of the thermal resistance of tubular geometries:
1 ρ  r2 
T=ρ = ln 
A 2π  r1 
(4)
Equation (4) is applicable for most internal to the cable
layers (T 1 , T 2 , T 3 ). For complicated geometries and for the
layers external to the cable, such as three-core cables, duct
banks, etc., heuristics are used. The external to the cable
thermal resistivity is commonly computed assuming that the
surface of the earth in the neighborhood of the cable
installation is an isothermal. Kennelly made this assumption
in 1893 and it is still being used. This assumption allows for
the application of the image method to compute the external
to the cable thermal resistance (T 4 ). The following
expression results from the image method:
1 ρ  4L 
T=ρ = ln 
A 2π  De 
(5)
The thermal resistance of the layers external to the cable
(T 4 ) must also include the duct when present, and the air
inside. The duct itself is of tubular geometry and it very
easy to model, however, the treatment of the air inside of a
duct is a complex matter. The heat transfer is dominated by
convection and radiation and not by conduction. There exist
simple formulas, which have been obtained experimentally
165
and that work fine for the conditions tested [5]. A software
code by Matlab is provided to calculate the ampacity at
different cases and the flowchart that explained the program
is shown in Figure 2.
3. Factors affecting cable ampacity
3.1 Effect of soil resistivity
Dry soils have much higher thermal resistivity than
moist soils. With sufficiently high ampacity thermal, run-
away conditions can occur. If cable current is high enough,
it will generate sufficient heat and if it is maintained for a
long enough time, the soil will become unstable and the
circuit will have to be de-rated or overheated. Cable
ampacity varies with change of soil resistivity, for both
with-conduit and the conduit-less cable. Cable ampacity is
proportional to soil conductivity; rising soil conductivity
dissipates more heat, and increase cable ampacity.
3.2 Effect of cable depth
Depth affects the ampacity of cables that buried with
conduit and conduit-less, in both homogeneous and
heterogeneous soil. Soil conductivity is reduced by
increasing the cable depth in the soil as well as less heat
dissipation, less ampacity. The closer the cable to earth’s
surface, the rate of cable ampacity changes will increase
[7].
4. Test arrangement
4.1 Theoretical study for ampacity
A computer program has been proposed using
MATLAB to calculate the current carrying capacity
(ampcity) for different underground cables. The flowchart
is presented in Figure (1). The program takes into account
the steady state conditions which based on the formulas in IEC
standards. Equation (1) is used to calculate the cable
ampacity and the parameters of the equation (1) should be
separately calculated dependant on the various factors like
cable construction types, installation types, installation
environment. Steady state conditions is considered when the
current flow through the cable is at a constant value and the
temperature of the cable is also constant i.e. the heat
generated is equal to the heat dissipated. The temperature
depends on the type of cable and XLPE construction is
chosen where the maximum temperature normally for
steady-state is 90°C.
Adel El-Faraskoury, et al., AEES, Vol. 1, No. 3, pp. 163-169, 2012 166

Start shape of the soil particles determines the surface contact

area between particles which affects the ability of the soil to
Read input data
1. Cable data
conduct heat. Figure 3 and Figure 4 show the variation of
2. Temp. data
3. Soil resistivity
ampacity for cable with soil resistivity and soil temperature,
respectively. For underground cable system the main heat
Calculate transfer mechanism is by conduction. Since, the
1. The outer diameter of the cable, sheath diameter and insulation
diameter and different thicknesses longitudinal dimension of a cable is always much larger
2. DC Resistance and AC resistance
3. Dielectric losses than the depth of the installation, the problem is considered
4. Sheath loss factor
5. Armor loss factor
6. Thermal resistivities
a two-dimensional heat conduction problem. Figure 5
shows the effect of depth on cable ampacity and Figure 6
Ampacity Calculation shows the variation of ampacity with cable temperature.

Flat Formation Trifoil Formation

Table 1. Comparison of cable ampacity between single
circuit and double circuits with manufactures
Emergency Steady state Emergency Steady state Ampacity
Bonded number
Double Single Double Double Single Double 240 400 630 800
bond bond bond bond bond bond
mm2 mm2 mm2 mm2
(Amp.) (Amp.) (Amp.) (Amp.)
Write the ampacity of the different cases

Single Flat 502 648 839 939

Ampacity Calculation for different cable depth Bonded
Trefoil 478 616 796 909

Flat Formation Trifoil Formation

Double Flat 435 584 702 780
Bonded
Write the ampacity of the different cases Trefoil 460 558 672 754

Ampacity Calculation for different soil temperature

Double Flat 484 649 778 865
Bonded
Emergency Trefoil 511 620 746 737
Flat Formation Trifoil Formation

Flat 497 640 829 935

Write the ampacity of the different cases
Manufacturers
Trefoil 445 550 774 863
Ampacity Calculation for different soil resistivity

1000
Flat Formation Trifoil Formation SoilRes for trfoil
SoilRes for flat
900
Write the ampacity of the different cases

End 800
Figure 2. Flowchart of the Matlab program used for ampacity
calculation
Current (A)

700

The MATLAB program is provided to calculate the cables

600
ampcity for single bonded, double bonded and double
bonded emergency with equal load. The ampacity is
500
calculated at different grounding mode and comparing it
with manufactures based on IEC and it is shown in Table I
and Figures from Figure 3 to Figure 6 for the following 400

conditions; flat and trefoil formation, soil resistivity is 1.2

°C.m/w, the ground temperature at 25°C for cable sample 300
0.5 1 1.5 2 2.5 3 3.5 4
38/66 kV [8]. The thermal resistivity of soft depends on the Soil Resitivity (oC w/m)
type of soil encountered as well as the physical conditions
Figure 3. Variation of cable ampacity with soil resistivity
of the soft. The conditions which most influence the
resistivity of a specific soil are the moisture content and dry
density. As the moisture content or dry density or both of a
soil increases, the soil resistivity decreases. The structural
composition of the soil also affects the soil resistivity. The
Adel El-Faraskoury, et al., AEES, Vol. 1, No. 3, pp. 163-169, 2012 167

800
4.2 Experimental study (Calibration of the
SoilTemp for trfoil temperature method)
SoilTemp for flat

750 The calibration should be carried out in a draught-free

situation at a temperature of 20 ± 5 ºC. Temperature
700
recorders should be used to measure the conductor, over-
sheath and ambient temperature simultaneously. The
Current (A)

calibration should be performed on a minimum cable length

650 10 m, taken from the same cable under test. IEC adopts a
cable system test approach and requires a minimum of 10 m
of the cable. The length should be such that the longitudinal
600
heat transfer to the cable ends does not affect the
temperature in the center 2 m of the cable by more than 1º
550 C. During calibration and during the test of the main loop
10 15 20 25 30 35 40 45
Degrees (C) should be calculated according with either IEC 60287 or
60853[9], based on the measured external temperature of
Figure 4. Effect of soil temperature on the ampacity of cable
the oversheath (TC S ). The measurement should be done
with a thermocouple at the hottest spot, attached to or under
820 the external surface. The hottest current should be adjusted
Depth for trfoil
Depth for flat to obtain the required value of the calculated conductor
800
temperature, based on the measured external temperature of
780 the over-sheath [9]. The cable that used for calibration
should be identical to that used for the test, and the way
760
(path) of heat should be identical. After stabilization has
been reached the following should be noted and drawing
Current (A)

740
the curve as in Figure 7.
720

- Ambient temperature
700
- Conductor temperature
680 - Over-sheath temperature
- Heating current
660

640
0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Depth (b)

Figure 5. Effect of depth on ampacity

900
Emerg flat
800 Emerg trfoil
Dbl Bond flat
700 Dbl Bond trfoil
Sng Bond flat
600 Sng Bond trfoil
Current (A)

500

400

300

200

100
Figure 7. Calibration of temperature for XLPE cable sample
0 38/66 kV – 1x 630 mm2
20 30 40 50 60 70 80 90 100 110
Cable Temp - Degrees (C)
The heating currents in both the reference loop and
Figure 6. Variation of cable ampacity with temperature
the test loop were kept equal at all time, thus the conductor
temperature of the reference loop in representative for the
conductor temperature of the test loop. The tests elevated
temperature is carried out two hours after thermal
Adel El-Faraskoury, et al., AEES, Vol. 1, No. 3, pp. 163-169, 2012 168

equilibrium has been established. it must develop a constants of high voltage cables. In this test, the cable
consistent heating cycle to maintain the conductor sample 38 /66 kV – CU/XLPE/LEAD/HDPE – 1x 630
temperature adjustment generally cannot be made in mm2 with 15m length as shown in Table II and Figure 8.
sufficient time during testing due to the large thermal time

Table2. Heating cycle for xlpe cables

xlpe – cu- 38/66kv- 1x 630 mm2

No. of Required Heating Heating Cooling Voltage

heating steady current at per cycle per Per
cycle conductor stable cycle cycle
temp. condition

Total Stable
ºC Amp. duration temp. hr hr 2U
20 hr hr 0

95-100 1600 8 2 16 2 72
4

Figure 8. Heating cycle for cable sample 38/66 kV – 1x 630 mm2

Figure 9. Variation of current with ambient temperature during test
Ambient temperature (Lab. Temperature) affects the period
heating current as shown in Figure 9. Figure 10 shows the
relation between heating current with conductor
temperature during heating per cycle. The heating current
varies with the ambient temperature during heating cycle. Steady
state conditions are considered when the current flow
through the cable is at a constant value and the temperature
of the cable is also constant i.e. the heat generated is equal
to the heat dissipated. The temperature depends on the type
of cable but XLPE construction is searched where the
maximum temperature normally for steady-state is 90ºC.
The IEC requirement is simply that the conductor be “at
this temperature” for at least 2 hours of the current on
period.

Figure 10. Variation of heating current conductor temperature

 Adel El-Faraskoury, et al., AEES, Vol. 1, No. 3, pp. 163-169, 2012
5. Conclusions
The theoretical and practical study for cable ampacity
estimation under steady state conditions shows that the
underground cable ampacity depends on the cable geometry
installation, its depth as well as on the soil thermal
resistivity. Cable ampacity is proportional to soil
conductivity; when soil conductivity increases, cable
ampacity will be increased. The results show that the cable
ampacity decreases with the increase of cable depth
installation under soil surface. By using MATLAB with the
steady state conditions based on IEC standards and comparing
with manufacturers, it gives good results. In facts that stand
out the importance of interaction with the manufacturers,
designer and installers of the line for attainment of coherent
data with the reality. The maximum operating temperature
of a cable is typically limited by its insulation material but
can also be limited by the maximum temperature which the
surrounding environment can be withstood without
degradation.
Acknowledgment
The authors would like to express his great thanks to the
team work of the Extra High Voltage Research Centre for
providing their facilities during this work.
References
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