CABLE SIZING - OVERVIEW
CABLE SIZING IS A VERY IMPORTANT STEP IN
ELECTRICAL ENGINEERING. SINCE ALL ELECTRICAL
EQUIPMENTS WOULD NOT FUNCTION WITHOUT A
CONDUCTOR RUNNING BETWEEN THE SOURCE
AND THE LOAD, CABLES MAKE UP A SIGNIFICANT
PORTION IN ELECTRICAL ENGINEERING.
IN TYPICAL EPC PROJECT, CABLE QTY (BASED ON
PERCENTAGE OF TOTAL BOQ ITEMS) MAKE UP
ABOUT 20-40%+ OF TOTAL ELECTRICAL COST.
CABLE SIZING - OVERVIEW
ALTHOUGH THE AMOUNT OF CABLES
DEPENDS ON THE SCOPE AND SIZE OF THE
PLANT, CABLE SIZING STILL REMAINS A
CRUCIAL ASPECT IN ELECTRICAL
ENGINEERING.
NOT ONLY DOES IT GOVERN THE COST OF
ELECTRICAL SYSTEM, IT ALSO GOVERNS THE
SAFETY OF THE ENTIRE ELECTRICAL SYSTEM.
CABLE SIZING - OVERVIEW
IF A CABLE IS NOT SIZE PROPERLY, THE
FOLLOWING THINGS COULD OCCUR:
- THE EQUIPMENT IS NOT POWERED
PROPERLY (INSUFFICIENT VOLTAGE)
- THE CABLE COULD OVERHEAT, CAUSING
INSULATION TO FAIL/PARTIAL DISCHARGE
AND FIRES TO OCCUR.
- AS A RESULT OF THE ABOVE, A WHOLE
SECTION OF CABLE TRAY / TRENCH COULD
BURN-OUT CAUSING PLANT FAILURE.
CABLE SIZING - CONSTRUCTION
BEFORE WE DELVE INTO THE PROCESS OF CABLE SIZING, LETS TAKE A LOOK AT A
TYPICAL CABLE CONSTRUCTION:
CU/XLPE/CTS/PVC/DTA/PVC
CABLE SIZING CONSTRUCTION
CABLE CONDUCTOR
THE CABLE CONDUCTOR CAN BE:
-ALUMINUM
-COPPER
SELECTION OF THESE ARE DEPENDENT ON
CLIENT, WITH A NOTABLE IN PRICE FOR
ALUMINUM, BUT WITH LESS AMPACITY
RATING COMPARED TO COPPER.
As per IEC 60502
CABLE SIZING CONSTRUCTION
CONDUCTOR SCREEN
THE CONDUCTOR SCREEN CAN BE:
-NON-METALLIC
-CONSISTS OF EXTRUDED SEMI-CONDUCTING
COMPOUND, WHICH MAY BE APPLIED ON
THE TOP OF THE SEMI CONDUCTING TAPE.
IT IS TYPICALLY A NON-METALLIC SEMI-
CONDUCTING SCREEN BEFORE INSULATION,
PROVIDED FOR ELECTRICAL SHIELDING IF
SPECIFIED BY THE CLIENT.
As per IEC 60502
CABLE SIZING CONSTRUCTION
INSULATION
THERMOPLASTIC:
-PVC
Insulating Max Conductor
THERMOSETTING: Compound Temperature C
-XLPE
Normal S.C
-EPR
-HEPR PVC (300mm2) 70 160
(>300mm2) 70 140
TYPICAL XLPE 90 250
INSULATION IS
EITHER PVC OR EPR & HEPR 90 250
XLPE.
As per IEC 60502
CABLE SIZING CONSTRUCTION
INSULATION SCREEN
THE CONDUCTOR SCREEN IS:
-NON-METALLIC, SEMI CONDUCTING IN
COMBINATION WITH A METALLIC LAYER.
-SEMI-CONDUCTING TAPE
IT IS TYPICALLY USED IN MV CABLES AT
THE REQUEST OF CLIENT, WHERE COPPER
TAPE SCREEN (CTS) IS USED FOR EARTH
FAULT CURRENT PATH.
As per IEC 60502
CABLE SIZING CONSTRUCTION
FILLER
INTERSTICES BETWEEN THE CORES ARE
FILLED WITH NON-HYGROSCOPIC FILLER
(WHICH IS USUALLY A SOFT POLYMER, LIKE
PVC), ALSO ON THE OUTSIDE OF THE
INSULATED CONDUCTORS.
THIS KEEPS THE CABLE CORES IN-PLACE
AND RETAINS THE CIRCULAR SHAPE OF
THE CABLE.
As per IEC 60502
CABLE SIZING CONSTRUCTION
BEDDING
BEDDING IS USUALLY EXTRUDED-PVC,
WHICH SERVES AS A PROTECTION OF THE
LAID-UP CORES, AND PROVIDES BEDDING
FOR CABLE ARMOUR.
As per IEC 60502
CABLE SIZING CONSTRUCTION
ARMOUR
CABLE ARMOURS CAN BE:
- GALVANIZED STEEL FLAT WIRE OR ROUND WIRE
- ALUMINIUM OR ALUMINIUM ALLOY FOR SINGLE-
CORE CABLES
- DOUBLE TAPE STEEL, GALVANIZED STEEL,
ALUMINIUM OR ALUMINIUM ALLOY
ARMOUR IS PROVIDED FOR MECHANICAL
PROTECTION OF CABLE. IT IS ALSO PROVIDED AS
REQUESTED BY CLIENT, AND USUALLY FOR
UNDERGROUND/TRENCH LAYED CABLES.
As per IEC 60502
CABLE SIZING CONSTRUCTION
OUTER SHEATH
- NORMALLY BLACK (OTHERWISE RED OR
ORANGE)
LV CABLES ARE USUALLY BLACK,
WHILE MV CABLES ARE RED
- PVC OR POLYETHYLENE
(THERMOPLASTIC)
- CHEMICAL ADDITIVES FOR CABLE
PROTECTION
As per IEC 60502
CABLE SIZING CONSTRUCTION
VOLTAGE SELECTION
VOLTAGE OF CABLES IS DESIGNATED AS:
U0/U (UM)
WHERE:
- U0 RATED POWER FREQUENCY VOLTAGE
BETWEEN CONDUCTOR & EARTH OR METALLIC
SCREEN
- U RATED POWER FREQUENCY VOLTAGE
BETWEEN CONDUCTORS
- UM MAXIMUM VALUE OF THE HIGHEST
SYSTEM VOLTAGE FOR WHICH EQUIPMENT MAY
BE USED
As per IEC 60502
CABLE SIZING CONSTRUCTION
VOLTAGE SELECTION
SOME EXAMPLES/COMMON IEC VOLTAGE
DESIGNATION OF CABLES ARE (NOTE,
UNITS IN THIS NOTATION ARE IN KV):
- LV CABLES : .6/1(1.2) OR TYPICALLY .6/1
- MV CABLES :
3.6/6(7.2), 6/10(12), 8.7/15(17.3), 12/20 (24)
As per IEC 60502
CABLE SIZING - CONSTRUCTION
ANY QUESTIONS?
CABLE SIZING CALCULATION
SIZING FOR CABLES IS DONE IN 3
AREAS/CRITERIAS:
1. FAULT LEVEL WITHSTAND CAPABILITY
(MINIMUM SIZE OF CABLE)
2. CONTINUOUS CURRENT CARRYING
CAPACITY (DERATING DUE TO
ENVIRONMENT)
3. VOLTAGE DROP ON CABLES (TERMINAL
VOLTAGE AT LOAD, DURING RUNNING &
START-UP)
CABLE SIZING CALCULATION
FAULT LEVEL WITHSTAND
CALCULATION FOR MINIMUM SIZE BASED ON SHORT CIRCUIT /
FAULT LEVEL WITHSTAND IS BASED ON THE FOLLOWING
FORMULA:
CABLE SIZING CALCULATION
FAULT LEVEL WITHSTAND
THE CONSTANT K IS DIFFERENT FOR COPPER & ALUMINUM
CONDUCTORS, WHICH IS ALSO DIFFERENT BASED ON THE TYPE OF
INSULATION (XLPE, OR PVC).
AS NOTED, K FOR XLPE INSULATED CABLES IS COMMONLY 143.1
(FOR SC I IN AMPERES) OR .1431 (FOR SC I IN KA).
THIS K IS DERIVED FROM THE FOLLOWING FORMULAS (BASED ON
IEC 60364-5-54):
(COPPER CONDUCTORS) (ALUMINUM CONDUCTORS)
CABLE SIZING CALCULATION
FAULT LEVEL WITHSTAND
IN THE FORMULA BEFORE:
INITIAL TEMPERATURE IS TYPICALLY CHOSEN FROM MAXIMUM OPERATING
TEMPERATURE OF THE CABLE.
WHILE THE FINAL TEMPERATURE IS TYPICALLY CHOSEN FROM THE LIMITING
TEMPERATURE OF THE INSULATION.
FOR THESE TEMPERATURES, ROUGHLY THE FOLLOWING TABLE IS FOLLOWED:
Max Operating Temperature
Material oC
Limiting Temperature oC
PVC 75 160
EPR 90 250
XLPE 90 250
CABLE SIZING CALCULATION
FAULT LEVEL WITHSTAND
MAXIMUM SHORT CIRCUIT IS BASED ON
THE KA RATING OF THE CONNECTED
SWITCHGEAR/MCC BUS.
CABLE SIZING CALCULATION
FAULT LEVEL WITHSTAND
FOR THE SHORT CIRCUIT DURATION, IN THEORY THIS WOULD BE BASED ON
THE SC WITHSTAND TIME OF THE SWITCHGEAR/MCC BUS AS WELL. ALTHOUGH
IT IS SAFE TO SIZE IT THIS WAY, THIS WILL CAUSE THE MINIMUM CABLE SIZE TO
BE OVERSIZED UN-REALISTICALLY.
THEREFORE, T HERE IS COMMONLY CONSIDERED TO BE THE TRIPPING TIME OF
THE BREAKER/FUSE CONNECTED TO THE CABLE.
FOR MV (VCB/ACB), THIS IS ROUGHLY .25 SECONDS.
FOR LV MCB/FUSE, THIS IS ROUGHLY .1 MS OR .001 SECONDS (SOMETIMES LESS).
TO GET AN MORE REALISTIC FIGURE, WE WOULD HAVE TO CONSULT WITH THE
VENDOR BREAKER CATALOGUE FOR THE ACTUAL OR STANDARD TRIPPING
TIME OF THE PROTECTIVE DEVICE.
CABLE SIZING CALCULATION
CONTINUOUS CURRENT CARRYING CAPACITY
CONSIDERATION FOR CONTINUOUS CURRENT
CARRYING CAPACITY IS MAINLY BASED ON
VENDOR CATALOGUES, LISTING VARIOUS
AMPERE RATINGS, FOR VARIOUS SIZES OF
CABLES.
THE AMPERE RATING LISTED IN A VENDOR
CATALOGUE CONSIDERS CERTAIN
ENVIRONMENT AND INSTALLATION
CONDITIONS.
CABLE SIZING CALCULATION
CONTINUOUS CURRENT CARRYING CAPACITY
THOSE CONDITIONS THAT AFFECT THE AMPACITY
OF CABLES ARE:
-THERMAL RESISTIVITY OF SOIL (IF BURIED)
-DEPTH OF LAYING (IF BURIED)
-AMBIENT TEMPERATURE (ABOVE/UNDER
GROUND)
-LAYING OF CONDUCTORS
THE CONDITIONS STATED BY VENDOR FOR THOSE
CONDITIONS NEED TO BE NOTED, BECAUSE THESE
WILL AFFECT THE DERATING FACTORS.
CABLE SIZING CALCULATION
CURRENT DERATING THERMAL RESISTIVITY
TYPICAL TABLE OF CORRECTION FACTORS FOR
THERMAL RESISTIVITY:
IN THIS CASE, VENDOR CATALOGUE PROVIDES DATA
WITH 2.2 K.M/W THERMAL RESISTIVITY.
IF SITE CONDITIONS SAYS THERMAL RESISTIVITY OF
SOIL IS 1.5 K.M/W, THEN THE CORRECTION FACTOR FOR
AMPACITY SHALL BE 1.1
CABLE SIZING CALCULATION
CURRENT DERATING DEPTH OF LAYING
FOR DEPTH
OF LAYING,
TYPICAL
TABLE OF
CORRECTION
FACTORS IS:
CABLE SIZING CALCULATION
CURRENT DERATING AMBIENT TEMPERATURE
AMBIENT TEMPERATURE IS CONSIDERED FOR BOTH UNDERGROUND AND
ABOVE GROUND CABLES.
TYPICAL CORRECTION FACTOR FOR AMBIENT TEMPERATURE ARE:
CABLE SIZING CALCULATION
CURRENT DERATING CABLE GROUPING
CABLE GROUPING IS BASED ON PLANNED/ACTUAL LAYING CONDITIONS.
PROXIMITY AND QUANTITY OF CABLES AFFECT THE RATING OF THE CABLES,
AS INDICATED IN A TYPICAL GROUPING TABLE AS FOLLOWS:
CABLE SIZING CALCULATION
CURRENT DERATING CABLE GROUPING
NOTE THAT CABLE GROUPING FACTORS ARE USUALLY
COMMON EITHER FOR ABOVE-GROUND
INSTALLATION / UNDERGROUND INSTALLATION. THIS
FACTOR IS MORE CLOSELY RELATED TO PROXIMITY OF
CABLES THAN LOCATION/TEMPERATURE.
FEW THINGS TO CONSIDER AS WELL:
- MV CABLES TYPICALLY HAS SPACE OF 2D CENTER-
TO-CENTER.
- LV CABLES TYPICALLY ARE ALWAYS TOUCHING
- WORST CASE TOUCHING CASE IS TYPICALLY TAKEN
FOR STANDARD OF CABLE SIZING.
CABLE SIZING CALCULATION
TOTAL DERATING FACTOR
SO AFTER DETERMINING THE CORRECTION
FACTORS BASED ON THE ABOVE POINTS, WE FIND
TOTAL DERATING FACTOR, AS FOLLOWS:
WHERE:
CABLE SIZING CALCULATION
TOTAL DERATING FACTOR
HENCE THE AMPERE RATING OF THE
CATALOGUE SHALL BE MULTIPLIED BY THIS
DERATING FACTOR TO OBTAIN THE
DERATED RATING OF THE CABLE, WHICH IS
USED FOR SIZING THE CABLE.
FOR EXAMPLE, FOR 3C X 50 MM2 CABLE, IF DF
IS .6, AND THE RATING AS PER CATALOGUE IS
192 A, THEN THE ACTUAL MAXIMUM RATING
TO CONSIDER IS:
192 A X .6 = 115 A
CABLE SIZING CALCULATION
VOLTAGE DROP
CABLE SIZING BASED ON VOLTAGE DROP
DEALS WITH THE RESISTANCE & REACTANCE
OF THE CABLE (DATA GIVEN BY VENDOR),
AND ALSO THE DISTANCE OF THE CABLE.
IN THEORY, THE LONGER THE DISTANCE, THE
LARGER THE VOLTAGE DROP. AND FOR LOW
VOLTAGE, THIS BECOMES INCREASINGLY
IMPORTANT, WHICH IS WHY LOW VOLTAGE
CABLES OFTEN END UP WITH MULTIPLE RUNS
OF CABLES.
CABLE SIZING CALCULATION
VOLTAGE DROP
THE CALCULATION FOR VOLTAGE DROP IS AS FOLLOWS:
WHERE:
CABLE SIZING
ANY QUESTIONS?
