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    Cable Sizing PDF

    Uploaded by

    kumar
    The document provides guidelines for selecting power cables based on motor ratings, voltage drop calculations, and short circuit capacity. Key points: - Minimum cable size is 3C x 185 sq.mm aluminum XLPE cable for voltages up to 6.6kV. - Cable size is selected based on motor nameplate current, voltage drop during starting and running per specifications, and a 40kA short circuit capacity for the 6.6kV system. - Sample calculations are shown for a 240 sq.mm aluminum XLPE cable connecting a primary dedusting fan motor rated for 260A at 6.6kV, with voltage drops of 0.48% during running and 0.60% during starting

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    © All Rights Reserved
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    Cable Sizing PDF

    Uploaded by

    kumar
    234 views8 pages
    The document provides guidelines for selecting power cables based on motor ratings, voltage drop calculations, and short circuit capacity. Key points: - Minimum cable size is 3C x 185 sq.mm aluminum XLPE cable for voltages up to 6.6kV. - Cable size is selected based on motor nameplate current, voltage drop during starting and running per specifications, and a 40kA short circuit capacity for the 6.6kV system. - Sample calculations are shown for a 240 sq.mm aluminum XLPE cable connecting a primary dedusting fan motor rated for 260A at 6.6kV, with voltage drops of 0.48% during running and 0.60% during starting

    Original Title

    117680976-cable-sizing.pdf

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    The document provides guidelines for selecting power cables based on motor ratings, voltage drop calculations, and short circuit capacity. Key points: - Minimum cable size is 3C x 185 sq.mm aluminum XLPE cable for voltages up to 6.6kV. - Cable size is selected based on motor nameplate current, voltage drop during starting and running per specifications, and a 40kA short circuit capacity for the 6.6kV system. - Sample calculations are shown for a 240 sq.mm aluminum XLPE cable connecting a primary dedusting fan motor rated for 260A at 6.6kV, with voltage drops of 0.48% during running and 0.60% during starting

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    234 views8 pages

    Cable Sizing PDF

    Uploaded by

    kumar
    The document provides guidelines for selecting power cables based on motor ratings, voltage drop calculations, and short circuit capacity. Key points: - Minimum cable size is 3C x 185 sq.mm aluminum XLPE cable for voltages up to 6.6kV. - Cable size is selected based on motor nameplate current, voltage drop during starting and running per specifications, and a 40kA short circuit capacity for the 6.6kV system. - Sample calculations are shown for a 240 sq.mm aluminum XLPE cable connecting a primary dedusting fan motor rated for 260A at 6.6kV, with voltage drops of 0.48% during running and 0.60% during starting

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 8
    At a glance
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    The key takeaways from the document are the methodology, formulas and factors considered for proper sizing of power cables for motor connections based on voltage drop, current rating and short circuit capacity.

    The different factors considered for cable sizing include the rated motor current, starting and running voltage drop, short circuit capacity of the system, cable ampacity ratings, cable resistance and reactance values.

    The formula used for voltage drop calculation is: Percentage Voltage Drop = (IR x Cable Resistance + IX x Cable Reactance) x Length / (Supply Voltage x Power Factor) where I is the current, R is the cable resistance, X is the cable reactance and L is the cable length.

    Philosophy of Cable Sizing Methodology

    1 General guideline for selection of Power Cables

    The min size of the cable shall be 3 C x 185 sq.mm. of type A2XFY for XLPE insulated cables
    ►
    as per IS : 7098 Part-II, Non-FRLS
    ► Supply System : 6600 V , +6%, -9% / 50 Hz, +3%, -6%, 3-ph

    Cable size for HT motors shall be selected on the basis of rated nameplate current, starting &
    ► running voltage drop as per specification and short circuit capacity of the system. The cable size
    shall be calculated based on the breaker opening time of 0.25 seconds

    ► Short circuit capacity of 6.6 kV is 40kA .


    AC motors of ratings in excess of 200KW upto 2000 KW shall be connected to 6.6 KV HT
    ►
    power supply system.
    2 Formulae used for calculation

    2.1 Voltage Drop Calculation

    √3 x IRATED x (RCAB|900C Cosφ r + XCAB Sinφ r) x Lr


    %VDROP = = -------------------------------------------------------------------------
    V x n x 10

    where,
    IRATED = Rated Motor Current Amps
    RCAB|900C = Resistance of Cable at 90 C 0
    Ohms/KM
    XCAB = Reactance of Cable Ohms/KM
    Lr = Length of Cable (run) mts
    V = Operating System Voltage Volts
    n = No of parallel path/run
    Cosφ r = Power Factor during running

    2.2 Voltage Dip Calculation

    √3 x IStart x (RCAB|900C Cosφ s + XCAB Sinφ s) x Ls


    %VDIP = = ------------------------------------------------------------------------
    V x n x 10
    where,
    IStart = Motor Starting Current Amps
    RCAB|900C = Resistance of Cable at 900C Ohms/KM
    XCAB = Reactance of Cable Ohms/KM
    Ls = Length of Cable (Start) mts
    V = Operating System Voltage Volts
    n = No of parallel path/run
    Cosφ s = Power Factor during start

    Prep By : Abhijit Mandal


    Page 1 of 8 I-MT OP PEP-EA2
    2.3 Minimum Crossection of Cable

    As per IEC - 60724 recomendation

    I2t = K2S2

    where

    Qc(β + 20) θf - θi
    K= ------------- x Loge 1 + ---------
    ρ20 θi + β
    where,
    I = Short Circuit Current Amps
    S = Cross Section of Cable sqmm
    t = Duration of Short Circuit sec
    O
    θf = Final temp after Short Circuit C
    O
    θi = Initial temp before Short Circuit C
    β = Reciprocal of temp co-efficient of resistance of current carrying component
    K = Constant
    Qc = Volumetric heat capacity of conductor material at 20OC J/OCmm3
    ρ20 = Electrical resistivity of conductor material at 20OC Ωmm

    3 Sample calculations for selection of Aluminium XLPE cable


    3.1 System Parameters / Conductor Parameters Remarks
    Supply Voltage = 6.6 kV (From CTS / GS03)
    Fault Level = 40 kA (From CTS / GS03)
    Fault Clearing Time = 0.25 sec (From CTS / GS03)
    Conductor Material , Insulation = Al , XLPE (From CTS / GS03)
    O
    Initial Temp of Cable Conductor = 90 C (From Manufacturer)
    O
    Final Temp of Cable Conductor = 250 C (From Manufacturer)
    O
    Recipro. of temp co-eff. of resistance = 228 C (From Manufacturer)
    O
    Resistivity of conductor Mat. at 20 C = 0.000028264 Ωmm (From Manufacturer)
    O O 3
    Vol. heat cap. of cond. Mat. at 20 C = 0.0025 J/ Cmm (From Manufacturer)
    K = 94.6 (Calculated)
    Required Min.Cross Section of Cable = 211 sqmm (Calculated)

    Selected Cable 240 sqmm Al, XLPE

    Prep By : Abhijit Mandal


    Page 2 of 8 I-MT OP PEP-EA2
    Primary Dedusting ID Fan Motor (HTSS to VFD Transformer)
    Calculations & Selected Cable Parameters (from Table - 1)
    Running Conditions Remarks
    Cable Route Length = 750 mts (From Layout)
    Cable Size Selected = 240 sqmm (Selected)
    Motor FL Current ( at 6.6 kV ) = 260 Amps @ 6.6 kV
    Power Factor (Run) = 0.91 (Typical Data)

    Cable Rating (at 40 0 C per run) = 395 A (Calculated)


    Cable Ampacity (with DF = 0.65) = 257 A (Calculated)
    No of Runs required = 2 No (Calculated)
    Calculated Voltage Drop (Run) 0.48 % (Calculated)
    Starting Conditions
    Cable Route Length = 750 mts (From Layout)
    Cable Size Selected = 240 sqmm (Selected)
    Locked Rotor Current/Nominal Current = 1.5 times ( VFD Driven)
    Motor Starting Current ( at 6.6 kV ) = 390 A (Calculated)
    No of Runs required = 2 No (Calculated)
    Calculated Voltage Drop (Start) 0.60 % (Calculated)

    Table - 1 : Cable Data from Manufacturer


    3C x 6.6/11 kV (UE) Al XLPE

    Conductor Rcab at 90
    Xcab at 90 degC STC (kA) Icab at 40 degC Derating
    Size degC IcabD (A)
    ohms/km for 1 Sec in air (A) Factor
    (sqmm) Ohms/km

    35 1.1100 0.144 3.3 125 0.65 81


    50 0.8200 0.137 4.7 150 0.65 98
    70 0.5670 0.129 6.6 190 0.65 124
    95 0.4100 0.123 9 230 0.65 150
    120 0.3240 0.117 11.3 260 0.65 169
    150 0.2640 0.114 14.2 295 0.65 192
    185 0.2110 0.105 17.39 335 0.65 218
    240 0.1600 0.106 22.6 395 0.65 257
    300 0.1300 0.103 28.3 450 0.65 293
    400 0.1000 0.099 37.7 520 0.65 338

    Prep By : Abhijit Mandal


    Page 3 of 8 I-MT OP PEP-EA2
    Primary Dedusting ID Fan Motor (VFD Transformer to Motor via VFD)
    Calculations & Selected Cable Parameters (from Table - 1)
    Running Conditions Remarks
    Cable Route Length = 200 mts (From Layout)
    Cable Size Selected = 240 sqmm (Selected)
    Motor FL Current ( at 4.16 kV ) = 415 Amps @ 4.16 kV
    Power Factor (Run) = 0.91 (Typical Data)

    Cable Rating (at 40 0 C per run) = 395 A (Calculated)


    Cable Ampacity (with DF = 0.65) = 257 A (Calculated)
    No of Runs required = 2 No (Calculated)
    Calculated Voltage Drop (Run) 0.33 % (Calculated)
    Starting Conditions
    Cable Route Length = 200 mts (From Layout)
    Cable Size Selected = 240 sqmm (Selected)
    Locked Rotor Current/Nominal Current = 1.5 times ( VFD Driven)
    Motor Starting Current ( at 4.16 kV ) = 623 A (Calculated)
    No of Runs required = 2 No (Calculated)
    Calculated Voltage Drop (Start) 0.40 % (Calculated)

    Table - 1 : Cable Data from Manufacturer


    3C x 6.6/11 kV (UE) Al XLPE

    Conductor Rcab at 90
    Xcab at 90 degC STC (kA) Icab at 40 degC Derating
    Size degC IcabD (A)
    ohms/km for 1 Sec in air (A) Factor
    (sqmm) Ohms/km

    35 1.1100 0.144 3.3 125 0.65 81


    50 0.8200 0.137 4.7 150 0.65 98
    70 0.5670 0.129 6.6 190 0.65 124
    95 0.4100 0.123 9 230 0.65 150
    120 0.3240 0.117 11.3 260 0.65 169
    150 0.2640 0.114 14.2 295 0.65 192
    185 0.2110 0.105 17.39 335 0.65 218
    240 0.1600 0.106 22.6 395 0.65 257
    300 0.1300 0.103 28.3 450 0.65 293
    400 0.1000 0.099 37.7 520 0.65 338

    Prep By : Abhijit Mandal


    Page 4 of 8 I-MT OP PEP-EA2
    Secondary Dedusting ID Fan Motor (HTSS to VFD Transformer)
    Calculations & Selected Cable Parameters (from Table - 1)
    Running Conditions Remarks
    Cable Route Length = 750 mts (From Layout)
    Cable Size Selected = 240 sqmm (Selected)
    Motor FL Current ( at 6.6 kV ) = 160 Amps @ 6.6 kV
    Power Factor (Run) = 0.91 (Typical Data)

    Cable Rating (at 40 0 C per run) = 395 A (Calculated)


    Cable Ampacity (with DF = 0.65) = 257 A (Calculated)
    No of Runs required = 1 No (Calculated)
    Calculated Voltage Drop (Run) 0.60 % (Calculated)
    Starting Conditions
    Cable Route Length = 750 mts (From Layout)
    Cable Size Selected = 240 sqmm (Selected)
    Locked Rotor Current/Nominal Current = 1.5 times ( VFD Driven)
    Motor Starting Current ( at 6.6 kV ) = 240 A (Calculated)
    No of Runs required = 1 No (Calculated)
    Calculated Voltage Drop (Start) 0.73 % (Calculated)

    Table - 1 : Cable Data from Manufacturer


    3C x 6.6/11 kV (UE) Al XLPE

    Conductor Rcab at 90
    Xcab at 90 degC STC (kA) Icab at 40 degC Derating
    Size degC IcabD (A)
    ohms/km for 1 Sec in air (A) Factor
    (sqmm) Ohms/km

    35 1.1100 0.144 3.3 125 0.65 81


    50 0.8200 0.137 4.7 150 0.65 98
    70 0.5670 0.129 6.6 190 0.65 124
    95 0.4100 0.123 9 230 0.65 150
    120 0.3240 0.117 11.3 260 0.65 169
    150 0.2640 0.114 14.2 295 0.65 192
    185 0.2110 0.105 17.39 335 0.65 218
    240 0.1600 0.106 22.6 395 0.65 257
    300 0.1300 0.103 28.3 450 0.65 293
    400 0.1000 0.099 37.7 520 0.65 338

    Prep By : Abhijit Mandal


    Page 5 of 8 I-MT OP PEP-EA2
    Secondary Dedusting ID Fan Motor (VFD Transformer to Motor)
    Calculations & Selected Cable Parameters (from Table - 1)
    Running Conditions Remarks
    Cable Route Length = 90 mts (From Layout)
    Cable Size Selected = 240 sqmm (Selected)
    Motor FL Current ( at 4.16 kV ) = 260 Amps @ 4.16 kV
    Power Factor (Run) = 0.91 (Typical Data)

    Cable Rating (at 40 0 C per run) = 395 A (Calculated)


    Cable Ampacity (with DF = 0.65) = 257 A (Calculated)
    No of Runs required = 2 No (Calculated)
    Calculated Voltage Drop (Run) 0.09 % (Calculated)
    Starting Conditions
    Cable Route Length = 90 mts (From Layout)
    Cable Size Selected = 240 sqmm (Selected)
    Locked Rotor Current/Nominal Current = 1.5 times ( VFD Driven)
    Motor Starting Current ( at 4.16 kV ) = 390 A (Calculated)
    No of Runs required = 2 No (Calculated)
    Calculated Voltage Drop (Start) 0.11 % (Calculated)

    Table - 1 : Cable Data from Manufacturer


    3C x 6.6/11 kV (UE) Al XLPE

    Conductor Rcab at 90
    Xcab at 90 degC STC (kA) Icab at 40 degC Derating
    Size degC IcabD (A)
    ohms/km for 1 Sec in air (A) Factor
    (sqmm) Ohms/km

    35 1.1100 0.144 3.3 125 0.65 81


    50 0.8200 0.137 4.7 150 0.65 98
    70 0.5670 0.129 6.6 190 0.65 124
    95 0.4100 0.123 9 230 0.65 150
    120 0.3240 0.117 11.3 260 0.65 169
    150 0.2640 0.114 14.2 295 0.65 192
    185 0.2110 0.105 17.39 335 0.65 218
    240 0.1600 0.106 22.6 395 0.65 257
    300 0.1300 0.103 28.3 450 0.65 293
    400 0.1000 0.099 37.7 520 0.65 338

    Prep By : Abhijit Mandal


    Page 6 of 8 I-MT OP PEP-EA2
    Gas Holder (GRP) Booster Fan 300 kW
    Calculations & Selected Cable Parameters (from Table - 1)
    Running Conditions Remarks
    Cable Route Length = 1000 mts (From Layout)
    Cable Size Selected = 240 sqmm (Selected)
    Motor FL Current ( at 6.6 kV ) = 29 Amps @ 6.6 kV
    Power Factor (Run) = 0.91 (Typical Data)

    Cable Rating (at 40 0 C per run) = 395 A (Calculated)


    Cable Ampacity (with DF = 0.65) = 257 A (Calculated)
    No of Runs required = 1 No (Calculated)
    Calculated Voltage Drop (Run) 0.15 % (Calculated)
    Starting Conditions
    Cable Route Length = 1000 mts (From Layout)
    Cable Size Selected = 240 sqmm (Selected)
    Locked Rotor Current/Nominal Current = 6 times ( DOL)
    Motor Starting Current ( at 6.6 kV ) = 175 A (Calculated)
    No of Runs required = 1 No (Calculated)
    Calculated Voltage Drop (Start) 0.71 % (Calculated)

    Table - 1 : Cable Data from Manufacturer


    3C x 6.6/11 kV (UE) Al XLPE

    Conductor Rcab at 90
    Xcab at 90 degC STC (kA) Icab at 40 degC Derating
    Size degC IcabD (A)
    ohms/km for 1 Sec in air (A) Factor
    (sqmm) Ohms/km

    35 1.1100 0.144 3.3 125 0.65 81


    50 0.8200 0.137 4.7 150 0.65 98
    70 0.5670 0.129 6.6 190 0.65 124
    95 0.4100 0.123 9 230 0.65 150
    120 0.3240 0.117 11.3 260 0.65 169
    150 0.2640 0.114 14.2 295 0.65 192
    185 0.2110 0.105 17.39 335 0.65 218
    240 0.1600 0.106 22.6 395 0.65 257
    300 0.1300 0.103 28.3 450 0.65 293
    400 0.1000 0.099 37.7 520 0.65 338

    Prep By : Abhijit Mandal


    Page 7 of 8 I-MT OP PEP-EA2
    LCSS Dedusting 2000 kVA
    Calculations & Selected Cable Parameters (from Table - 1)
    Running Conditions Remarks
    Cable Route Length = 750 mts (From Layout)
    Cable Size Selected = 240 sqmm (Selected)
    Trafo FL Current ( at 6.6 kV ) = 175 Amps @ 6.6 kV
    Power Factor (Run) = 0.80 (Typical Data)

    Cable Rating (at 40 0 C per run) = 395 A (Calculated)


    Cable Ampacity (with DF = 0.65) = 257 A (Calculated)
    No of Runs required = 1 No (Calculated)
    Calculated Voltage Drop (Run) 0.66 % (Calculated)

    Table - 1 : Cable Data from Manufacturer


    3C x 6.6/11 kV (UE) Al XLPE

    Conductor Rcab at 90
    Xcab at 90 degC STC (kA) Icab at 40 degC Derating
    Size degC IcabD (A)
    ohms/km for 1 Sec in air (A) Factor
    (sqmm) Ohms/km

    35 1.1100 0.144 3.3 125 0.65 81


    50 0.8200 0.137 4.7 150 0.65 98
    70 0.5670 0.129 6.6 190 0.65 124
    95 0.4100 0.123 9 230 0.65 150
    120 0.3240 0.117 11.3 260 0.65 169
    150 0.2640 0.114 14.2 295 0.65 192
    185 0.2110 0.105 17.39 335 0.65 218
    240 0.1600 0.106 22.6 395 0.65 257
    300 0.1300 0.103 28.3 450 0.65 293
    400 0.1000 0.099 37.7 520 0.65 338

    Prep By : Abhijit Mandal


    Page 8 of 8 I-MT OP PEP-EA2

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