INSTALLATION SYSTEM SIZING - STUDY NOTES
1. Meaning of Installation System Sizing
Installation system sizing is the process of determining the correct electrical ratings and physical
sizes of all components in an electrical installation so that the system operates safely, efficiently,
and complies with electrical regulations.
It includes sizing of: Conductors (cables) Protective devices Conduits and trunking Distribution
boards Earthing and bonding conductors Switchgear and accessories 2. Purpose of Installation
System Sizing Prevent overheating of cables Avoid excessive voltage drop Ensure protective
devices operate correctly Reduce fire and electric shock risks Improve system reliability and
lifespan Meet electrical code requirements 3. Components That Require Sizing
a) Electrical Load Lighting loads Socket outlet loads Fixed appliances Motors and machinery b)
Conductors Phase conductors Neutral conductors Protective earth conductors c) Protective
Devices Fuses MCBs MCCBs RCCBs / ELCBs d) Containment Systems Conduits Trunking
Cable trays e) Earthing System Earth electrodes Earthing conductors Bonding conductors 4.
Steps in Performing Installation System Sizing
STEP 1: Identify and List Electrical Loads
Prepare a load schedule showing: Type of load Power rating (W or kW) Quantity Location Example:
LED Lights: 12 W × 10 = 120 W Socket Outlets: 300 W × 8 = 2400 W Cooker: 3000 W × 1 = 3000
W STEP 2: Calculate Total Connected Load
Total Load (W) = Sum of Individual Loads STEP 3: Apply Diversity Factor
Maximum Demand = Connected Load × Diversity Factor Typical Diversity Factors: Lighting = 0.9
Socket outlets = 0.6 – 0.7 Domestic appliances = 0.5 – 0.8 STEP 4: Calculate Design Current
Single-Phase System: I = P / V
Three-Phase System: I = P / (√3 × V) Where: I = Current (A) P = Power (W) V = Voltage (V) STEP
5: Select Cable Size
Consider: Current-carrying capacity Installation method Ambient temperature Grouping of cables
Voltage drop limits Typical Copper Cable Sizes: 1.5 mm² – Lighting circuits 2.5 mm² – Socket
outlets 6.0 mm² – Cookers 10.0 mm² – Sub-mains STEP 6: Check Voltage Drop
Permissible Voltage Drop: Lighting = 3% Other circuits = 5% Voltage Drop = I × L × mV/A/m If
voltage drop exceeds the limit, increase cable size. STEP 7: Size Protective Devices
Protective devices must: Protect the cable Trip under fault conditions Selection Rule: Ib ≤ In ≤ Iz
Where: Ib = Design current In = Protective device rating Iz = Cable current-carrying capacity STEP
8: Size Conduits and Trunking
Calculate total cable cross-sectional area Apply the 40% maximum fill rule Example: 20 mm conduit
→ Maximum fill ≈ 78 mm² Avoid overcrowding to prevent overheating and difficulty in pulling cables.
STEP 9: Size Distribution Board (DB)
Consider: Number of outgoing circuits Space for spare ways Total load capacity Future expansion
STEP 10: Size Earthing and Bonding System
Size earthing conductor according to phase conductor size Ensure it can safely carry fault current
Select suitable earth electrode length and quantity to achieve required earth resistance 5. Factors
Affecting Installation System Sizing Type of building Supply voltage and phase Length of cable
run Environmental conditions Installation method Regulatory requirements 6. Common Errors in
System Sizing Ignoring diversity Undersizing cables Oversizing protective devices Failing to
consider voltage drop Poor earthing design 7. Importance of Proper System Sizing Prevents
electrical fires Improves energy efficiency Ensures user safety Reduces maintenance costs
Enhances compliance with standards