1.
0 PURPOSE
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The purpose of this document is to determine the electrical cable sizes for project ------------------------------
of ----------------------------
2.0 REFERENCE DOCUMENTS
CODE / DOCUMENT NO. DISCRIPTION
--------------------------------- Specification for Electrical Design Philosophy
--------------------------------- Specification for General Electrical.
--------------------------------- Specification for Electrical design.
--------------------------------- Electrical load list
3.0 ELECTRICAL SYSTEMS AND VOLTAGES
-6.6kV - 50Hz -3 phase - Resistance grounded.
Power
- 415V - 50Hz -3 phase - 4 wire – Solidly Grounded.
Lighting and small power - 240V AC - 50Hz - 1 Phase - 3 wire.
Critical Lighting, control & metering. -110V - DC.
Auxiliary Power Supply: - 240VAC - 50Hz - 1 phase - 3 wire.
4.0 BASIS OF DESIGN
The basic criteria to be taken into consideration are as follows:
o
a) Design ambient air temperature : 35 C
b) Method of Installation : Cables shall be laid in trays / trench
c) All the cable routing in process area shall be above ground on the pipe rack with prefabricated
GI cable trays / under ground in concrete trenches. The concrete trench shall be filled with sand
d) HV / MV & Control cables shall be laid in touching formation.
e) Cable trays for HV / MV / Control cables shall be separate, minimum vertical distance of
300 mm shall be maintained between two cable trays.
5.0 CABLE DATA
5.1 Rated voltage
System Voltage Rated voltage
HV 6.6kV
MV 1.1kV
5.2 Insulation & Conductor 2 of 26
a) HV Cable : XLPE insulated, Aluminium conductor,
Screened, Steel wire armoured, PVC outer
sheath, Flame retardant.
2
b) MV Cables above 16 mm : XLPE insulated, Aluminium conductor,
Screened, Steel wire armoured, PVC outer
sheath, Flame retardant.
2
c) MV cables up to 16mm : XLPE insulated Copper conductor, Screened,
Steel wire armoured / Steel strip armoured,
PVC outer sheath, Flame retardant.
d) Control cables : XLPE insulated, copper conductor,
Screened, Steel wire armoured / steel strip
armoured, PVC outer sheath, Flame retardant.
5.3 Cable size
a) Maximum size of cable :
1 HV Cable : ----------------------------
2 MV Cable : ----------------------------
b) Medium Voltage Power
2 2 2
Cable : 2.5 mm upto 16 mm (Copper) and above 16 mm (Aluminium)
5.4 Short circuit withstand time for HV Cables shall be as follow:
Description Time in Sec.
Incommer Feeder 1.0
Outgoing Feeder 0.2
Plant Feeder 0.6
6.0 PERMISSIBLE VOLTAGE DROP
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6.1 The maximum voltage drop in various sections of the electrical system under steady
state conditions at full load shall be within the limits stated in the following table:
Maximum
[Link] System Element Permissible
Voltage Drop
1 Bus duct or cable between transformer secondary and HV switch board or 0.5%
PCC / PMCC.
Cable between PCC / PMCC and MCC or auxiliary switch board.
2 i) MCC / Auxiliary Switch board near PCC / PMCC. 0.5%
ii) MCC / Auxiliary Switch board situated remote from PCC / PMCC. 2.5%
3 Cables between HV switch board and HV motor. 3%
4 Cables between PCC / PMCC and Motor. 5.5%
5 Cables between MCC (situated near PCC / PMCC) and Motors. 5%
6 Cable between MCC (situated remote from PCC/PMCC) & Motors. 3%
7 Cables between auxiliary switch board / LDB and lighting panel. 1 to 1.5 %
8 Circuit between lighting panels and lighting points. 4%
9 DC supply circuit (Electrical controls). 5%
10 DCDB to Control room. 2%
11 UPS outgoing circuits. 5%
6.2 The maximum voltage drop during start-up of large motor and / or motor reacceleration conditions
shall be within the limits stated below :
Max. Permissible
[Link] System Element
Voltage Drop
1 Cables between HV switchboard (6.6 kV) and Motor 5%
2 Cables between MV switchboard (415V) and Motor 15%
7.0 METHOD
7.1 LV Cable selection shall be made according to the following sequence:
1 Selection of the minimum cross-section according to the current carrying capacity (S1). The
current value to be taken into account is the rated current carrying capacity of cable
multiplied by the overall derating factor.
2 Selection of the minimum cross-section required to match the acceptable voltage drop (S2). 4 of 26
For motor feeders, voltage drop under both conditions viz. during start up & during normal
running shall be checked.
3 Selection of the most stringent value among S1& S2.
7.2 HV Cable selection shall be made according to the following sequence :
1 Selection of minimum size of cable considering maximum short circuit current (K1).
2 Selection of the minimum cross-section according to the current carrying capacity (K2).
The Current value to be taken into account is the rated current carrying capacity of cable
multiplied by the overall derating factor.
3 Selection of the minimum cross-section required to match the acceptable voltage drop (K3).
For motor feeders, voltage drop under both conditions viz. during start up & during
normal running shall be checked.
4 Selection of most stringent value among K1, K2 & K3.
8.0 CABLE SIZING
8.1 CABLE DERATING FACTOR:
8.1.1 Low Voltage Cable Derating Factor (In open air on Trays)
The overall derating for all the LV cables laid in open air (on trays) / Cable trench is
based upon the following factors:
1) Air Temperature (C A): -
The maximum ambient air Temperature is 41oC as per the
document ‘ Specification for Electrical Design philosophy
CA = 1.04
2) Cable Grouping (CG): -
For Multi core cables laid in open air with cable touching and 2 nos. of trays in vertical5 of 26
formation with a minimum 2 [Link] cables per tray or rack.
CG = 0.8
Accordingly the overall derating factor for all the LV cables laid in open air (on trays)
is given by: -
Overall Derating Factor = [CA] x [CG]
= 0.83
8.1.2 Low Voltage Cable Derating Factor ( in Ground)
1) Depth of laying (CD) -
The derating factor for the depth of laying of 150 cm is given by:
[CD] = 1
2) Rating Factor for Variation in Thermal resistivity of soil (CT) -
The derating Factor for Thermal Resitiity of [Link]/w is given by:
[CT] = 0.9
3) Rating Factor for variation in Ground Temperature (CGT) -
The derating factor for ground temperature of 35 deg. is given by:
[CGT] = 0.9
4) Cable Grouping (CG ) -
For Multi core cable laid directly in ground in horizontal formation when spacing between
Cables is 0 cm and 4 nos of Cables in Group.
[CG] = 0.6
Accordingly the overall derating factor for all the LV cables laid in ground is given by: -
Overall Derating Factor = [CD] x [CT] x [CGT ] x [ CG]
= 0.50
8.1.3 High Voltage Cable Derating Factor (In open air on Trays)
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1) Air Temperature (C A): -
The maximum ambient air Temperature is 41oC as per the
document ‘ Specification for Electrical Design philosophy
[CA] = 0.8
2) Cable Grouping (CG): -
For Single core cables laid in open air with cable touching and 2 nos. of trays in vertical
formation with a minimum 3 [Link] Trefoil.
[CG] = 0.93
Accordingly the overall derating factor for all the HV cables laid in open air (on trays)
is given by: -
Overall Derating Factor = [CA] x [CG]
= 0.74
8.1.4 High Voltage Cable Derating Factor ( in Ground)
1) Depth of laying (CD) -
The derating factor for the depth of laying of 120 cm is given by:
[CD] = 0.96
2) Rating Factor for Variation in Thermal resistivity of soil (CT) -
The derating Factor for Thermal Resitiity of 200 [Link]/w is given by:
[CT] = 0.89
3) Rating Factor for variation in Ground Temperature (CGT) -
The derating factor for ground temperature of 30 deg. is given by:
[CGT] = 1
4) Cable Grouping (CG ) -
For Single core cable laid directly in ground in horizontal formation when spacing between
Trefoils is 45 cm and 2 nos of Trefoils in Group.
[CG] = 0.88
Accordingly the overall derating factor for all the LV cables laid in ground is given by: - 7 of 26
Overall Derating Factor = [CD] x [CT] x [CGT ] x [ CG]
= 0.75
8.2 VOLTAGE DROP
The voltage drop is calculated by the following formula:
a) Single-Phase Feeder:
- Single-phase voltage drop
∆U = 2xLxI(R cosΦ + X sinΦ)/n
b) Three-Phase Feeder:
- Three phase voltage drop
∆U = 1.732xLxIL(R cosΦ + X sinΦ)/n
c) Three-Phase Motor using DOL starting method:
- Three phase voltage drop while motor in running condition
∆U = 1.732xLxIL(R cosΦ + X sinΦ)/n
- Three phase voltage drop while motor in starting condition
∆U = 1.732 x L x IST (R cos ΦST + X sin ΦST) / n
Where:
L = Length (km)
R = Core resistance (ohm/km)
X = Core inductance (ohm/km)
IL = Rated line current (A)
IST = Starting current (A) of motor
cosΦ = Power factor
cosΦST = Starting power factor
n = No. of cable runs
d) HV cable selection: (Breaker feeder) 8 of 26
The minimum Cable cross section area to withstand expected short circuit current
and its duration is defined by following equation:
S=Ix t mm 2
k
Where,
t = Duration of fault current in secs.
2
S = Minimum Cross sectional area of the conductor in mm
I = Value of fault current in kA.
k = 0.094 for XLPE Al. cables
0.13 for XLPE CU. cables
8.3 Typical Voltage Drop Calculations
8.3.1 HT Cable Sizing (For Motor Feeder)
A) As per the Clause 8.2d above,the minimum Size required for HV Application is given by :
S= I x t mm 2
k
I= 40 kA
t= 1 Sec.
k = 0.094
2
S = 425.5 mm
Hence selected cable size (for Motor feeder) is2R x 3C x 240 [Link]
B) Off Gas Compressor (213-K-101A) = 2000 kW
The maximum current carrying capacity (Ampacity) of the 3C x 240 [Link] cable is
390 Amps.
Hence the Overall derated ampacity of the cable is = 390 x 0.75 x 2 Amps
= 586.46 Amps
Full Load current of Motor = 130.00 Amps
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Total derated current for 2 run of 3C x 240 [Link] cable is 586.46 Amps ,which is higher
than rated load current of 130.00 Amps.
C) Voltage Drop Calculation
C1) Voltage Drop while motor is running
∆U = 1.732xLxIL(R cosΦ + X sinΦ)/n
Where,
L= 1.55 km
R = 0.16 ohm/km
X = 0.085 ohm/km
Cos Φ = 0.85
Sin Φ = 0.53
No. of Cable Runs = 2
η = 0.95
Voltage Level = 11 kV
IL = 2000 /( 1.732 x 0.85 x 11 x 0.95 )
= 130.0 Amps
Applying Above Equation,
∆U = 31.55 V
% ∆U = ( 31.5 x 100)/ 11000
= 0.29 % ( < 3 % )
Hence,Voltage drop during running condition is within the Permissible limits of 3 %.
C2) Motor start voltage drop,
∆U = 1.732xLxIST(R cosΦST + X sinΦST)/n
Where,
L= 1.55 km
R = 0.16 ohm/km
X = 0.085 ohm/km
Cos ΦST = 0.25
Sin ΦST = 0.97
No. of Cable Runs = 2
η = 0.95 10 of 26
Voltage Level = 11 kV
IST = IL x 5.5
= 715 Amps
Applying Above Equation,
∆U = 117.4 V
% ∆U = ( 117. x 100)/ 11000
= 1.07 % ( < 5 % )
Hence,Voltage drop during Starting condition is within the Permissible limits of 5 %.
8.3.2 LV Motor Feeder
Vaccum heater Insulator-Forsed draft (211-F-001A) = 132 kW
A) Selected Cable Size is 4R-3C x 300 mm 2
The maximum current carrying capacity (Ampacity) of the 3C x 300 [Link] cable is
604.40 Amps.
Hence the Overall derated ampacity of the cable is = 305 x 0.49 x 4 Amps
= 604.40 Amps
Full Load current of Motor = 214.8 A
Total derated current for 4R x 3C x 300 [Link] cable is 604.40 Amps, which is higher
than rated load current of 214.78 Amps.
B) Voltage Drop Calculation:
B1) Voltage Drop while motor is running
∆U = 1.732xLxIL(R cosΦ + X sinΦ)/n
Where,
L= 0.59 km
R = 0.13 ohm/km
X = 0.071 ohm/km
Cos Φ = 0.9
Sin Φ = 0.44 11 of 26
No. of Cable Runs = 4
η = 0.95
Voltage Level = 0.415 kV
IL = 132 /( 1.732 x 0.9 x 0.415 x 0.95 )
= 214.8 Amps
Applying Above Equation,
∆U = 8.12 V
% ∆U = ( 8.11 x 100) / 415
= 1.96 % ( < 5% )
Hence,Voltage drop during running condition is within the Permissible limits of 5 %.
B2) Motor start voltage drop,
∆U = 1.732xLxIST(R cosΦST + X sinΦST)/n
Where,
L= 0.59 km
R = 0.13 ohm/km
X = 0.071 ohm/km
Cos Φ = 0.25
Sin Φ = 0.97
No. of Cable Runs = 4
η = 0.95
Voltage Level = 0.415 kV
IST = IL x 5.5
= 1181 Amps
Applying Above Equation,
∆U = 30.56 V
% ∆U = ( 30.55 x 100) / 415
= 7.36 % ( < 10 % )
Hence,Voltage drop during Starting condition is within the Permissible limits of 10 %.
8.3.3 Voltage drop in Cable from PMCC to MCC 12 of 26
Selected Cable Size is 4R of 3.5C x 300 mm 2
Load of MCC = 295 kW
Voltage Drop is given by
∆U = 1.732xLxIL(R cosΦ + X sinΦ)/n
Where,
L= 0.06 km
R = 0.12 ohm/km
X = 0.086 ohm/km
Cos Φ = 0.85
Sin Φ = 0.53
No. of Cable Runs = 4
η = 0.96
Voltage Level = 0.415 kV
IL = 295 /(1.732 x 0.415 x 0.85 x 0.96 ) Amps
= 503 Amps
Applying Above Equation,
∆U = 1.92 V
% ∆U = ( 1.92 x 100) / 415
= 0.46 % ( < 0.5 % )
Hence,Voltage drop is within the Permissible limits of 0.5 %.
8.3.4 230V, 1ph Circuit between Lighting Panel & Lighting Points
Selected Cable Size is 3C x 2.5 mm 2
Max. Load per circuit = 0.90 kW
Voltage Drop is given by
∆U =2xLxI(R cosΦ + X sinΦ)/n
Where,
L = 0.095 km
R = 8.87 ohm/km
X = 0.119 ohm/km
Cos Φ = 0.90
Sin Φ = 0.44
No. of Cable Runs = 1
Voltage Level = 0.23 kV 13 of 26
I = 0.9 /( 0.23 x 0.9 ) Amps
= 4.35 Amps
Applying Above Equation,
∆U = 6.64 V
% ∆U = ( 6.63 x 100) / 230
= 2.89 % ( < 3 % )
Hence,Voltage drop is within the Permissible limits of 3 %.
8.3.5 UPS Feeder
Selected Cable Size is 1R x 2C x 35 mm 2
Max. Load = 10 kW
Voltage Drop is given by
∆U =2xLxI(R cosΦ + X sinΦ)/n
Where,
L= 0.05 km
R = 1.04 ohm/km
X = 0.097 ohm/km
Cos Φ = 0.90
Sin Φ = 0.44
No. of Cable Runs = 1
Voltage Level = 0.24 kV
I = 10 /( 0.24 x 0.9 ) Amps
= 46.30 Amps
Applying Above Equation,
∆U = 4.53 V
% ∆U = ( 4.52 x 100) / 240
= 1.89 % ( < 5 % )
Hence,Voltage drop is within the Permissible limits of 5 %.
9.0 ATTACHMENTS