HINLJR00BUA-ED00002a DC Cable Sizing Calculation

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POWER SYSTEMS
TABLE DES MODIFICATIONS / MODIFICATIONS TABLE

REV
A
ETABLI
VERIFIE
APPROUVE
ESTABLISHED
CHECKED
APPROVED
MURUGIAH
DHS
VIKAS
HINLJR00BUA-ED00002/Rev A
DATE
19.7.10
MODIFICATIONS
FIRST ISSUE.
STAT.
GFE
Page 2
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POWER SYSTEMS
CONTENTS
1
PURPOSE
REFERENCE DOCUMENT
2.1 REFERENCE STANDARDS
BASIC DATA
3.1 ENVIRONMENTAL CONDITIONS AND DESIGN CRITERIA

3.2 ELECTRICAL NETWORK DATA
5
5
TECHNICAL SPECIFICATION:
4.1 TYPE OF CABLE

4.2 INSTALLATION METHOD
5
6
CABLE SIZING METHOD
5.1 CURRENT CARRYING CAPACITY CRITERIA

5.2 SHORT CIRCUIT CRITERIA
5.3 VOLTAGE DROP CRITERIA
6
8
9
CIRCUIT BREAKER SELECTION
CALCULATION SHEET
ANNEXURE-I : CURRENT RATING, RESISTANCE & REACTANCE
10
ANNEUXRE-II : TEMPERATURE CORRECTION FACTOR
11
10
ANNEUXRE-III : GROUP RATING FACTORS
12
ATTACHMENT 1:
CALCULATION SHEETS (220V DC SYSTEM)
ATTACHMENT 2:
CALCULATION SHEETS (48V DC SYSTEM)
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POWER SYSTEMS
PURPOSE
The purpose of the document is to define the basis of calculation of 220V & 48V DC Power Cable
Sizes for all the DC Distribution boards.
2.1
REFERENCE DOCUMENT
HINLJR20BUA-FD00001: 220 V DC System Single Line Diagram
HINLJR20BUA-FE00001: 220 V DC System Design memorandum
HINLJR20BUA-ED00001: 220 V DC System Power Balance
HINLJR20BUD-FD00001: 48 V DC System Single Line Diagram
HINLJR20BUD-FE00001: 48 V DC System Design memorandum
HINLJR20BUD-ED00001: 48 V DC System Power Balance
REFERENCE STANDARDS
IEC 60364-4-43
Electrical Instalations of Building Protection Against Over Current
IEC 60364-5-52
Electrical Instalations of Building Selection and Erection of

Electrical Equipment Wiring System
IEC 60364-5-54
Selection and Erection of Electrical Equipment Earthing

Arrangements, Protective Conductors and Protective Bonding
Conductors
IEEE Std 241
Recommended Practice For Electrical Power System In Commercial

Building
IS 1554 - Part 1
PVC insulated (heavy duty) electric cables specification: For working

voltages upto and including 1 100 V
IS 7098 - Part 1
Cross-Linked Polyetelene Insulated thermoplastic sheathed cables

specification: For working voltages upto and including 1 100 V
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POWER SYSTEMS
3
3.1
BASIC DATA
ENVIRONMENTAL CONDITIONS AND DESIGN CRITERIA
In particular, the electrical and control equipment will be designed for the following ambient
conditions:
3.2
Pollution level
Level III as per IS
Altitude
<1000 Meter
Location of devices
Outdoor
Maximum ambient temperature
42 C
Minimum ambient temperature
12.5 C
Design ambient temperature for Electrical equipment
50 C
Relative humidity
40% approx at 42oC
Maximum humidity
85%
Seismic zone
Zone II as per IS 1893
ELECTRICAL NETWORK DATA

The equipment supplied shall be designed to operate under the following electrical environment:
4
4.1
Rated Voltage
220 V & 48V DC
Variation Range
10 %
Earthing Mode
Un-earthed
TECHNICAL SPECIFICATION:
TYPE OF CABLE
Insulation ..........................................................................XLPE
Core
..........................................................................Single / Multi core
Voltage grade .....................................................................1100V

Maximum normal operating temperature............................900C
Maximum short time operating temperature.......................2500C for 1sec.
Conductor Material .............................................................Al / Cu
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POWER SYSTEMS
4.2
INSTALLATION METHOD
Cable
..........................................................................Perforated Tray / Ladder Type
Single core cables ...............................................................Single layer laying with trefoil formation

[Refer Doc. HINLJR000BB FE00001]
Multi core cables.................................................................Multi layer laying (without exceeding the
90% height of cable tray) and Cable
surfaces are touching [Refer Doc.
HINLJR000BB FE00001]
Buried cables ......................................................................Multi layer laying and Cable surfaces are
touching
5
CABLE SIZING METHOD

Cable sizing and selection is based on the following criteria:-
5.1
Current carrying capacity under normal operating condition
Current carrying capacity under short-circuit condition and
Voltage drop
CURRENT CARRYING CAPACITY CRITERIA

The current carrying capacity of a cable de-rates due to
a)
b)
ambient temperature
accumulation of cable/installation of cable)
Such adaptation is done considering de-rating factors for ambient temperature and cable installation
as described hereunder:Iz
(Rated Capacity of cable)
In / Kd
(Required Capacity of Feeder)
Where
Iz
rated current of cable (Annexure-I)
Kd
cable current carrying capacity de-rating factor
Further Kd is calculated as
Kd
K x K2 x Kg
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POWER SYSTEMS
Where,
K
= correction factor for ambient temperature (Annexure-III)
K2
Sun exposition factor which is
For cable screened from sun rays
0.8
For cable exposed to air with black sheath
0.9
For cable exposed to air with light colour sheath
Cable installation de-rating factor (Annexure-IV)
Kg
The maximum permanent current (In) of a feeder is given as

In
Sn
U
Where Sn
Nominal apparent power of the feeder
System voltage (220V for 220V DC System)
Size of the cable selected shall ensure
I d Iz
Where Iz is the rated current carrying capacity of the cable (Refer Annexure-I).
5.1.1 AMBIENT TEMPERATURE CORRECTION FACTOR

Temperature correction factor for an ambient temperature equal to 500 C, will be
Kt
0.9 (Annexure-III)
5.1.2 SUN EXPOSITION FACTOR

Ks
Sun exposition factor which is
For cable screened from sun rays
0.8
For cable exposed to air with black sheath
0.9
For cable exposed to air with light colour sheath
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POWER SYSTEMS
5.1.3 GROUPING FACTOR

Multi core cables
As per the installation method adopted for multi core cables as per IEC 60364-5-52 (Annexure-IV),
the installation group rating factor shall be suitably selected.
Perforated trays, Laying configuration of 6 cables and 3 trays, Kg = 0.71
5.2
SHORT CIRCUIT CRITERIA

The minimum cable cross-sectional area S is selected such that the maximum thermal stress in the
cable during short circuit does not reach the maximum permissible limit. The selection criteria is
given as (IEC 60364-4-43)
K2 S2 I t
Where
i t
:-
Energy let-through of the associated circuit breaker (As per

breaker manufacturer data)
:=
Cable constant which is given as
Qc ( + 20)
ln (1 +
20
( f i )
( + i )
(IS 3043)
Where
Qc
Volumetric heat capacity of the conductor material in J/oC mm3

(See Annexure IV)
20
= Electrical resistivity of conducting material at 20oC in . mm. (See Annexure IV)
= Reciprocal of temperature coefficient of resistivity of the conducting material at

0oC
= Initial temperature of conductor in oC
= Final temperature of conductor in oC
Thus the value of cable constant

For XLPE copper cable, K = 143
For XLPE aluminium cable K =94
Page 8
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POWER SYSTEMS
5.3
VOLTAGE DROP CRITERIA

The minimum cable cross-sectional area, S (in mm2) is calculated in such a way that the voltage drop
from the station service board / unit auxiliary board up to the consumer is less than or equal to 4%.
(IEC 60364-5-52)
Voltage drop
V
(2 x In x R x L) / 1000
Resistance of the cable in / Km, (Annexure-II)
In
Current in the feeder current A,
Length of cable in meter.
Where R
CIRCUIT BREAKER SELECTION

Circuit breakers rating is selected as per the connected load (i.e. maximum current in the feeder, In)
so as to confirm that the rated current of the circuit breaker is greater than the maximum permanent
load in the feeder.
1.
Thermal setting (Ith) of the circuit breaker/ current rating of CB is greater than or equal to
connected load, In.
2.
Icu with or without association with upstream breaker Icu Upstream Board.
CALCULATION SHEET
Please refer to Attachment 1.
Page 9
POWER SYSTEMS
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ANNEXURE-I : CURRENT RATING, RESISTANCE & REACTANCE
Page 10
POWER SYSTEMS
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ANNEUXRE-II : TEMPERATURE CORRECTION FACTOR
Page 11
POWER SYSTEMS
10
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ANNEUXRE-III : GROUP RATING FACTORS
Page 12
POWER SYSTEMS
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Page 13
ATTACHMENT 1 : CALCULATION SHEETS (220V DC POWER CABLES)
Sl. No. Rev
FROM EQUIPMENT
TO EQUIPMENT
DESIGNATION
DESIGNATION
LOAD
Consumption/O CURRENT IN
Voltage
utput Power
Amp
[V]
[W]
(In)
CABLE
TYPE
CABLE
RATED
LENGTH
No. OF SELECTED
CAPACITY RESISTANCE
RUNS CABLE SIZE
(m)
(/Km)
OF CABLE
mm2
(Iz)
Kt
Ks
Kg
REQUIRED PROTECTIVE
DEVICE
CAPACITY OF
Kd = (Kt x
FEEDER (A) RATING (A)
Ks x Kg)
(In / Kd)
(Ir)
K2S2
(kA2s)
LETPERMISSIBLE
THROUGH
VOLTAGE
(kA2s)
DROP (Vr)
RUNNING
VOLTAGE
DROP (Vpr)
BATTERY BANK 1
Positive Terminal
BATTERY TERMINAL BOX 1
220
300
XLPE-AL
1Cx500
693
0.082
18.062
0.9
0.78
0.702
427.35
400
2209
2.1
0.89
Negative Terminal
220
300
XLPE-AL
1Cx500
693
0.082
18.062
0.9
0.78
0.702
427.35
400
2209
2.1
0.89
TERMINAL BOX 1
BATTERY CHARGER 1
220
300
XLPE-AL
1Cx500
1386
0.082
59.6328
0.9
0.78
0.702
427.35
400
2209
2.1
1.6
1.47
BATTERY CHARGER 1
220V MAIN DISTRIBUTION BOARD
220
300
XLPE-AL
1Cx500
1386
0.082
23.2758
0.9
0.78
0.702
427.35
400
2209
2.1
0.7
0.57
Positive Terminal
220
300
XLPE-AL
1Cx500
693
0.082
18
0.9
0.71
0.639
469.48
400
2209
2.1
0.89
Negative Terminal
220
300
XLPE-AL
1Cx500
693
0.082
18
0.9
0.71
0.639
469.48
400
2209
2.1
0.89
TERMINAL BOX 2
BATTERY CHARGER 2
220
300
XLPE-AL
1Cx500
1386
0.082
60
0.9
0.71
0.639
469.48
400
2209
2.1
1.6
1.47
BATTERY CHARGER 2
220V MAIN DISTRIBUTION BOARD
220
300
XLPE-AL
1Cx500
1386
0.082
23
0.9
0.71
0.639
469.48
400
2209
2.1
0.7
0.57
BATTERY BANK 2
DCDB Load Bus-1
DCDB Load Bus-1
EXCITATION PANEL UNIT 1
220
1200
5.45
XLPE-Cu
2Cx6
64
3.94
38
0.9
0.71
0.639
8.54
10
0.74
4.5
1.62
DCDB Load Bus-1
LUBRICATING SYSTEM STARTER UNIT 1
220
18500
84.09
XLPE-AL
2Cx95
542
0.409
111
0.9
0.71
0.639
131.60
125
79.74
0.7
4.5
3.81
LUBRICATING SYSTEM PUMP UNIT 1
220
18500
84.09
XLPE-AL
2Cx95
542
0.409
20
0.9
0.71
0.639
131.60
125
79.74
0.7
0.69
DCDB Load Bus-1
HP OIL INJECTION STARTER UNIT 1
220
7500
34.09
XLPE-AL
2Cx70
221
0.565
111
0.9
0.71
0.639
53.35
63
43.30
4.5
4.27
HP OIL INJECTION PUMP UNIT 1
220
7500
34.09
XLPE-AL
2Cx70
221
0.565
20
0.9
0.71
0.639
53.35
63
43.30
0.77
DCDB Load Bus-1
GENERATOR BRAKING CUBICLE UNIT 1
220
200
0.91
XLPE-Cu
2Cx2.5
32
9.5
111
0.9
0.71
0.639
1.42
0.13
4.5
1.92
DCDB Load Bus-1
GENERATOR FIELD FLASHING UNIT 1
220
22000
100.00
XLPE-AL
2Cx95
271
0.409
38
0.9
0.71
0.639
156.49
200
79.74
0.85
4.5
3.08
DCDB Load Bus-1
MAIN GOVERNOR PANEL UNIT 1
220
300
1.36
XLPE-Cu
2Cx2.5
32
9.5
64
0.9
0.71
0.639
2.13
0.13
4.5
1.65
DCDB Load Bus-1
LOCAL GOVERNOR PANEL UNIT 1
220
300
1.36
XLPE-Cu
2Cx2.5
32
9.5
64
0.9
0.71
0.639
2.13
0.13
4.5
1.65
10
DCDB Load Bus-1
CONTROL AND PROTECTION BOARD UNIT 1
220
600
2.73
XLPE-Cu
2Cx6
64
3.94
64
0.9
0.71
0.639
4.27
0.74
4.5
1.37
11
DCDB Load Bus-1
GSU TRANSFORMER UNIT 1
220
55.5
0.25
XLPE-Cu
2Cx2.5
32
9.5
87
0.9
0.71
0.639
0.39
0.13
4.5
0.42
12
DCDB Load Bus-1
GSU TRANSFORMER UNIT 1 (Standby)
220
0.00
XLPE-AL
2Cx35
145
1.11
87
0.9
0.71
0.639
0.00
10.82
4.5
0.00
13
DCDB Load Bus-1
UNIT AUXILIARY BOARD 1
220
150
0.68
XLPE-Cu
2Cx2.5
32
9.5
44
0.9
0.71
0.639
1.07
0.13
4.5
0.57
14
DCDB Load Bus-1
220
1200
5.45
XLPE-Cu
2Cx6
64
3.94
41
0.9
0.71
0.639
8.54
10
0.74
4.5
1.76
15
DCDB Load Bus-1
220
18500
84.09
XLPE-AL
2Cx70
442
0.565
89
0.9
0.71
0.639
131.60
125
43.30
0.7
4.5
4.25
16
220
18500
84.09
XLPE-AL
2Cx70
442
0.565
20
0.9
0.71
0.639
131.60
125
43.30
0.7
0.95
17
DCDB Load Bus-1
220
7500
34.09
XLPE-AL
2Cx70
221
0.565
89
0.9
0.71
0.639
53.35
63
43.30
4.5
3.44
18
220
7500
34.09
XLPE-AL
2Cx70
221
0.565
20
0.9
0.71
0.639
53.35
63
43.30
0.77
19
DCDB Load Bus-1
220
200
0.91
XLPE-Cu
2Cx2.5
32
9.5
89
0.9
0.71
0.639
1.42
0.13
4.5
1.54
20
DCDB Load Bus-1
220
22000
100.00
XLPE-AL
2Cx95
271
0.409
41
0.9
0.71
0.639
156.49
200
79.74
0.85
4.5
3.36
21
DCDB Load Bus-1
220
300
1.36
XLPE-Cu
2Cx2.5
32
9.5
55
0.9
0.71
0.639
2.13
0.13
4.5
1.42
22
DCDB Load Bus-1
220
300
1.36
XLPE-Cu
2Cx2.5
32
9.5
55
0.9
0.71
0.639
2.13
0.13
4.5
1.42
23
DCDB Load Bus-1
220
600
2.73
XLPE-AL
2Cx16
88
2.44
55
0.9
0.71
0.639
4.27
2.26
4.5
0.73
24
DCDB Load Bus-1
220
55.5
0.25
XLPE-Cu
2Cx2.5
32
9.5
80
0.9
0.71
0.639
0.39
0.13
4.5
0.38
25
DCDB Load Bus-1
220
0.00
XLPE-AL
2Cx25
117
1.53
80
0.9
0.71
0.639
0.00
5.52
4.5
0.00
26
DCDB Load Bus-1
220
150
0.68
XLPE-Cu
2Cx2.5
32
9.5
36
0.9
0.71
0.639
1.07
0.13
4.5
0.47
27
DCDB Load Bus-1
220
1200
5.45
XLPE-Cu
2Cx4
51
5.9
47
0.9
0.71
0.639
8.54
10
0.33
4.5
3.04
28
DCDB Load Bus-1
220
18500
84.09
XLPE-AL
2Cx70
442
0.565
71
0.9
0.71
0.639
131.60
125
43.30
0.7
4.5
3.39
29
220
18500
84.09
XLPE-AL
2Cx70
442
0.565
20
0.9
0.71
0.639
131.60
125
43.30
0.7
0.95
30
DCDB Load Bus-1
220
7500
34.09
XLPE-AL
2Cx70
221
0.565
71
0.9
0.71
0.639
53.35
63
43.30
4.5
2.74
31
220
7500
34.09
XLPE-AL
2Cx70
221
0.565
20
0.9
0.71
0.639
53.35
63
43.30
0.77
32
DCDB Load Bus-1
220
200
0.91
XLPE-Cu
2Cx2.5
32
9.5
71
0.9
0.71
0.639
1.42
0.13
4.5
1.23
33
DCDB Load Bus-1
220
22000
100.00
XLPE-AL
2Cx95
271
0.409
47
0.9
0.71
0.639
156.49
200
79.74
0.85
4.5
3.87
34
DCDB Load Bus-1
220
300
1.36
XLPE-Cu
2Cx2.5
32
9.5
46
0.9
0.71
0.639
2.13
0.13
4.5
1.18
35
DCDB Load Bus-1
220
300
1.36
XLPE-Cu
2Cx2.5
32
9.5
46
0.9
0.71
0.639
2.13
0.13
4.5
1.18
36
DCDB Load Bus-1
220
600
2.73
XLPE-AL
2Cx16
88
2.44
46
0.9
0.71
0.639
4.27
2.26
4.5
0.61
37
DCDB Load Bus-1
220
55.5
0.25
XLPE-Cu
2Cx2.5
32
9.5
102
0.9
0.71
0.639
0.39
0.13
4.5
0.49
38
DCDB Load Bus-1
220
0.00
XLPE-AL
2Cx25
117
1.53
102
0.9
0.71
0.639
0.00
5.52
4.5
0.00
39
DCDB Load Bus-1
220
150
0.68
XLPE-Cu
2Cx2.5
32
9.5
30
0.9
0.71
0.639
1.07
0.13
4.5
0.39
40
DCDB Load Bus-1
SWITCHYARD SUB DISTRIBUTION BOARD LOAD BUS 1
220
5820
26.45
XLPE-AL
2Cx95A
542
0.41
329
0.9
0.71
0.639
41.40
100
79.74
0.5
4.5
3.57
41
DCDB Load Bus-1
STATION AUXILIARY CONTROL AND PROTECTION BOARD
220
260
1.18
XLPE-Cu
2Cx2.5
32
9.5
41
0.9
0.71
0.639
1.85
0.13
4.5
0.91
sheet 1 of 4
Sl. No. Rev
FROM EQUIPMENT
TO EQUIPMENT
DESIGNATION
DESIGNATION
LOAD
Voltage
utput Power
Amp
[V]
[W]
(In)
CABLE
TYPE
CABLE
RATED
LENGTH
No. OF SELECTED
CAPACITY RESISTANCE
RUNS CABLE SIZE
(m)
(/Km)
OF CABLE
mm2
(Iz)
Kt
Ks
Kg
REQUIRED PROTECTIVE
DEVICE
CAPACITY OF
Kd = (Kt x
Ks x Kg)
(In / Kd)
(Ir)
K2S2
(kA2s)
LETPERMISSIBLE
THROUGH
VOLTAGE
(kA2s)
DROP (Vr)
RUNNING
VOLTAGE
DROP (Vpr)
42
DCDB Load Bus-1
220
1400
6.36
XLPE-Cu
2Cx6
64
3.94
67
0.9
0.71
0.639
9.96
16
0.74
0.09
4.5
3.36
43
DCDB Load Bus-1
220
1400
6.36
XLPE-Cu
2Cx6
64
3.94
89
0.9
0.71
0.639
9.96
16
0.74
0.09
4.5
4.44
44
DCDB Load Bus-1
220
1400
6.36
XLPE-AL
2Cx16
88
2.44
110
0.9
0.71
0.639
9.96
16
2.26
0.09
4.5
3.42
45
DCDB Load Bus-1
INTAKE GATE / DAM CUBICLE
220
100
0.45
XLPE-Cu
2Cx2.5
32
9.5
56
0.9
0.71
0.639
0.71
0.13
4.5
0.49
46
DCDB Load Bus-1
MOSAIC MIMIC BOARD
220
125
0.57
XLPE-Cu
2Cx2.5
32
9.5
65
0.9
0.71
0.639
0.89
0.13
4.5
0.70
47
DCDB Load Bus-1
RESERVE BOARD - 1
220
500
2.27
XLPE-Cu
2Cx2.5
32
9.5
66
0.9
0.71
0.639
3.56
0.13
4.5
2.85
48
DCDB Load Bus-1
RESERVE BOARD - 2
220
500
2.27
XLPE-Cu
2Cx2.5
32
9.5
45
0.9
0.71
0.639
3.56
0.13
4.5
1.94
49
DCDB Load Bus-1
RESERVE BOARD - 3
220
500
2.27
XLPE-Cu
2Cx2.5
32
9.5
77
0.9
0.71
0.639
3.56
0.13
4.5
3.31
50
DCDB Load Bus-1
STATION AUXILIARY BOARD 1
220
150
0.68
XLPE-Cu
2Cx2.5
32
9.5
65
0.9
0.71
0.639
1.07
0.13
4.5
0.85
51
DCDB Load Bus-1
STATION AUXILIARY BOARD 2
220
150
0.68
XLPE-Cu
2Cx2.5
32
9.5
55
0.9
0.71
0.639
1.07
0.13
4.5
0.71
52
DCDB Load Bus-1
11kV GCB SWITCH BOARD FOR UNIT - 1
220
600
2.73
XLPE-AL
2Cx16
88
2.44
48
0.9
0.71
0.639
4.27
2.26
4.5
0.64
53
DCDB Load Bus-1
220
600
2.73
XLPE-AL
2Cx16
88
2.44
34
0.9
0.71
0.639
4.27
10
2.26
4.5
0.45
54
DCDB Load Bus-1
220
600
2.73
XLPE-AL
2Cx16
88
2.44
48
0.9
0.71
0.639
4.27
10
2.26
4.5
0.64
55
DCDB Load Bus-1
220
600
2.73
XLPE-AL
2Cx16
88
2.44
34
0.9
0.71
0.639
4.27
10
2.26
4.5
0.45
56
DCDB Load Bus-1
11kV LAVT PANEL FOR UNIT - 6
220
600
2.73
XLPE-Cu
2Cx4
51
5.9
117
0.9
0.71
0.639
4.27
10
0.33
4.5
3.76
57
DCDB Load Bus-1
GSU RTCC Panel UNIT - 1
220
200
0.91
XLPE-Cu
2Cx2.5
32
9.5
50
0.9
0.71
0.639
1.42
10
0.13
4.5
0.86
3.55
DCDB Load Bus-2
DCDB Load Bus-2
220
1200
5.45
XLPE-Cu
2Cx4
51
5.9
55
0.9
0.71
0.639
8.54
10
0.33
4.5
DCDB Load Bus-2
220
18500
84.09
XLPE-AL
2Cx70
442
0.565
80
0.9
0.71
0.639
131.60
125
43.30
0.7
4.5
3.82
220
18500
84.09
XLPE-AL
2Cx70
442
0.565
20
0.9
0.71
0.639
131.60
125
43.30
0.7
0.95
DCDB Load Bus-2
220
7500
34.09
XLPE-AL
2Cx70
221
0.565
80
0.9
0.71
0.639
53.35
63
43.30
4.5
3.09
220
7500
34.09
XLPE-AL
2Cx70
221
0.565
20
0.9
0.71
0.639
53.35
63
43.30
0.77
DCDB Load Bus-2
220
200
0.91
XLPE-Cu
2Cx2.5
32
9.5
80
0.9
0.71
0.639
1.42
0.13
4.5
1.39
DCDB Load Bus-2
220
22000
100.00
XLPE-AL
2Cx95
542
0.409
55
0.9
0.71
0.639
156.49
200
79.74
0.85
4.5
2.26
DCDB Load Bus-2
220
300
1.36
XLPE-Cu
2Cx2.5
32
9.5
69
0.9
0.71
0.639
2.13
0.13
4.5
1.78
DCDB Load Bus-2
220
300
1.36
XLPE-Cu
2Cx2.5
32
9.5
69
0.9
0.71
0.639
2.13
0.13
4.5
1.78
10
DCDB Load Bus-2
220
600
2.73
XLPE-Cu
2Cx6
64
3.94
67
0.9
0.71
0.639
4.27
0.74
4.5
1.44
11
DCDB Load Bus-2
220
55.5
0.25
XLPE-Cu
2Cx2.5
32
9.5
124
0.9
0.71
0.639
0.39
0.13
4.5
0.59
12
DCDB Load Bus-2
220
0.00
XLPE-AL
2Cx25
117
1.53
124
0.9
0.71
0.639
0.00
5.52
4.5
0.00
13
DCDB Load Bus-2
220
150
0.68
XLPE-Cu
2Cx2.5
32
9.5
40
0.9
0.71
0.639
1.07
0.13
4.5
0.51
14
DCDB Load Bus-2
220
1200
5.45
XLPE-Cu
2Cx6
64
3.94
94
0.9
0.71
0.639
8.54
10
0.74
4.5
4.03
15
DCDB Load Bus-2
220
18500
84.09
XLPE-AL
2Cx95
542
0.409
101
0.9
0.71
0.639
131.60
125
79.74
0.7
4.5
3.46
16
220
18500
84.09
XLPE-AL
2Cx70
442
0.565
20
0.9
0.71
0.639
131.60
125
43.30
0.7
0.95
17
DCDB Load Bus-2
220
7500
34.09
XLPE-AL
2Cx70
221
0.565
101
0.9
0.71
0.639
53.35
63
43.30
4.5
3.88
18
220
7500
34.09
XLPE-AL
2Cx70
221
0.565
20
0.9
0.71
0.639
53.35
63
43.30
0.77
19
DCDB Load Bus-2
220
200
0.91
XLPE-Cu
2Cx2.5
32
9.5
101
0.9
0.71
0.639
1.42
0.13
4.5
1.74
20
DCDB Load Bus-2
220
22000
100.00
XLPE-AL
2Cx95
542
0.409
94
0.9
0.71
0.639
156.49
200
79.74
0.85
4.5
3.83
21
DCDB Load Bus-2
220
300
1.36
XLPE-Cu
2Cx2.5
32
9.5
90
0.9
0.71
0.639
2.13
0.13
4.5
2.34
22
DCDB Load Bus-2
220
300
1.36
XLPE-Cu
2Cx2.5
32
9.5
90
0.9
0.71
0.639
2.13
0.13
4.5
2.34
23
DCDB Load Bus-2
220
600
2.73
XLPE-Cu
2Cx4
51
5.9
89
0.9
0.71
0.639
4.27
0.33
4.5
2.85
24
DCDB Load Bus-2
220
55.5
0.25
XLPE-Cu
2Cx2.5
32
9.5
145
0.9
0.71
0.639
0.39
0.13
4.5
0.70
25
DCDB Load Bus-2
220
0.00
XLPE-AL
2Cx25
117
1.53
145
0.9
0.71
0.639
0.00
5.52
4.5
0.00
26
DCDB Load Bus-2
220
150
0.68
XLPE-Cu
2Cx2.5
32
9.5
75
0.9
0.71
0.639
1.07
0.13
4.5
0.97
27
DCDB Load Bus-2
220
1200
5.45
XLPE-Cu
2Cx6
64
3.94
97
0.9
0.71
0.639
8.54
10
0.74
4.5
4.17
28
DCDB Load Bus-2
220
18500
84.09
XLPE-AL
2Cx95
542
0.409
123
0.9
0.71
0.639
131.60
125
79.74
0.7
4.5
4.24
29
220
18500
84.09
XLPE-AL
2Cx70
442
0.565
20
0.9
0.71
0.639
131.60
125
43.30
0.7
0.95
30
DCDB Load Bus-2
220
7500
34.09
XLPE-AL
2Cx95
271
0.409
123
0.9
0.71
0.639
53.35
63
79.74
4.5
3.44
31
220
7500
34.09
XLPE-AL
2Cx70
221
0.565
20
0.9
0.71
0.639
53.35
63
43.30
0.77
32
DCDB Load Bus-2
220
200
0.91
XLPE-Cu
2Cx2.5
32
9.5
123
0.9
0.71
0.639
1.42
0.13
4.5
2.13
33
DCDB Load Bus-2
220
22000
100.00
XLPE-AL
2Cx95
542
0.409
97
0.9
0.71
0.639
156.49
200
79.74
0.85
4.5
3.97
34
DCDB Load Bus-2
220
300
1.36
XLPE-Cu
2Cx2.5
32
9.5
112
0.9
0.71
0.639
2.13
0.13
4.5
2.90
35
DCDB Load Bus-2
220
300
1.36
XLPE-Cu
2Cx2.5
32
9.5
112
0.9
0.71
0.639
2.13
0.13
4.5
2.90
36
DCDB Load Bus-2
220
600
2.73
XLPE-Cu
2Cx4
51
5.9
110
0.9
0.71
0.639
4.27
0.33
4.5
3.54
sheet 2 of 4
Sl. No. Rev
FROM EQUIPMENT
TO EQUIPMENT
DESIGNATION
DESIGNATION
LOAD
Voltage
utput Power
Amp
[V]
[W]
(In)
CABLE
TYPE
CABLE
RATED
LENGTH
No. OF SELECTED
CAPACITY RESISTANCE
RUNS CABLE SIZE
(m)
(/Km)
OF CABLE
mm2
(Iz)
Kt
Ks
Kg
REQUIRED PROTECTIVE
DEVICE
CAPACITY OF
Kd = (Kt x
Ks x Kg)
(In / Kd)
(Ir)
K2S2
(kA2s)
LETPERMISSIBLE
THROUGH
VOLTAGE
(kA2s)
DROP (Vr)
RUNNING
VOLTAGE
DROP (Vpr)
37
DCDB Load Bus-2
220
55.5
0.25
XLPE-Cu
2Cx2.5
32
9.5
166
0.9
0.71
0.639
0.39
0.13
4.5
0.80
38
DCDB Load Bus-2
220
0.00
XLPE-AL
2Cx35
145
1.11
166
0.9
0.71
0.639
0.00
10.82
4.5
0.00
39
DCDB Load Bus-2
220
150
0.68
XLPE-Cu
2Cx2.5
32
9.5
83
0.9
0.71
0.639
1.07
0.13
4.5
1.07
40
DCDB Load Bus-2
SWITCHYARD SUB DISTRIBUTION BOARD LOAD BUS 2
220
5820
26.45
XLPE-AL
2Cx95A
542
0.41
329
0.9
0.71
0.639
41.40
100
79.74
0.5
4.5
3.57
41
DCDB Load Bus-2
STATION AUXILIARY CONTROL AND PROTECTION BOARD
220
260
1.18
XLPE-Cu
2Cx2.5
32
9.5
41
0.9
0.71
0.639
1.85
0.13
4.5
0.91
42
DCDB Load Bus-2
220
1400
6.36
XLPE-Cu
2Cx6
64
3.94
64
0.9
0.71
0.639
9.96
16
0.74
0.09
4.5
3.20
43
DCDB Load Bus-2
220
1400
6.36
XLPE-Cu
2Cx4
51
5.9
55
0.9
0.71
0.639
9.96
16
0.33
0.09
4.5
4.12
44
DCDB Load Bus-2
220
1400
6.36
XLPE-Cu
2Cx4
51
5.9
46
0.9
0.71
0.639
9.96
16
0.33
0.09
4.5
3.42
45
DCDB Load Bus-2
INTAKE GATE / DAM CUBICLE
220
100
0.45
XLPE-Cu
2Cx2.5
32
9.5
56
0.9
0.71
0.639
0.71
0.13
4.5
0.49
46
DCDB Load Bus-2
MOSAIC MIMIC BOARD
220
125
0.57
XLPE-Cu
2Cx2.5
32
9.5
65
0.9
0.71
0.639
0.89
0.13
4.5
0.70
47
DCDB Load Bus-2
220
600
2.73
XLPE-AL
2Cx16
88
2.44
55
0.9
0.71
0.639
4.27
10
2.26
4.5
0.73
48
DCDB Load Bus-2
220
600
2.73
XLPE-AL
2Cx16
88
2.44
55
0.9
0.71
0.639
4.27
10
2.26
4.5
0.73
49
DCDB Load Bus-2
220
600
2.73
XLPE-Cu
2Cx6
64
3.94
70
0.9
0.71
0.639
4.27
10
0.74
4.5
1.50
50
DCDB Load Bus-2
220
600
2.73
XLPE-Cu
2Cx6
64
3.94
74
0.9
0.71
0.639
4.27
10
0.74
4.5
1.59
51
DCDB Load Bus-2
GSU RTCC Panel UNIT - 1
220
200
0.91
XLPE-Cu
2Cx2.5
32
9.5
50
0.9
0.71
0.639
1.42
10
0.13
4.5
0.86
SWYD DCDB
DCDB bus-1
Unit-1 Bay Marshalling Kiosk
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
119
0.9
0.71
0.639
1.56
0.13
4.5
2.25
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
119
0.9
0.71
0.639
1.56
0.13
4.5
2.25
Unit-1 circuit breaker
220
220
1.00
XLPE-Cu
5Cx2.5A
28
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.62
Bus Isolator -1
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.62
Bus Isolator -2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
58
0.9
0.71
0.639
1.56
0.13
4.5
1.11
DCDB bus-2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
119
0.9
0.71
0.639
1.56
0.13
4.5
2.25
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
119
0.9
0.71
0.639
1.56
0.13
4.5
2.25
220
220
1.00
XLPE-Cu
5Cx2.5A
28
9.5
18
0.9
0.71
0.639
1.56
0.13
4.5
0.34
Bus Isolator -1
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.62
10
Bus Isolator -2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
58
0.9
0.71
0.639
1.56
0.13
4.5
1.11
11
DCDB bus-1
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
157
0.9
0.71
0.639
1.56
0.13
4.5
2.99
12
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
157
0.9
0.71
0.639
1.56
0.13
4.5
2.99
13
220
220
1.00
XLPE-Cu
5Cx2.5A
28
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.62
14
Bus Isolator -1
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.62
15
Bus Isolator -2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
58
0.9
0.71
0.639
1.56
0.13
4.5
1.11
16
DCDB bus-2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
157
0.9
0.71
0.639
1.56
0.13
4.5
2.99
17
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
157
0.9
0.71
0.639
1.56
0.13
4.5
2.99
18
220
220
1.00
XLPE-Cu
5Cx2.5A
28
9.5
18
0.9
0.71
0.639
1.56
0.13
4.5
0.34
19
Bus Isolator -1
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.62
20
Bus Isolator -2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
58
0.9
0.71
0.639
1.56
0.13
4.5
1.11
21
DCDB bus-1
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
196
0.9
0.71
0.639
1.56
0.13
4.5
3.72
22
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
196
0.9
0.71
0.639
1.56
0.13
4.5
3.72
23
220
220
1.00
XLPE-Cu
5Cx2.5A
28
9.5
18
0.9
0.71
0.639
1.56
0.13
4.5
0.34
24
Bus Isolator -1
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.62
25
Bus Isolator -2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
58
0.9
0.71
0.639
1.56
0.13
4.5
1.11
26
DCDB bus-2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
196
0.9
0.71
0.639
1.56
0.13
4.5
3.72
27
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
196
0.9
0.71
0.639
1.56
0.13
4.5
3.72
28
220
220
1.00
XLPE-Cu
5Cx2.5A
28
9.5
18
0.9
0.71
0.639
1.56
0.13
4.5
0.34
29
Bus Isolator -1
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.62
30
Bus Isolator -2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
58
0.9
0.71
0.639
1.56
0.13
4.5
1.11
31
IVT Isolator -1
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
51
0.9
0.71
0.639
1.56
0.13
4.5
0.97
32
IVT Isolator -2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
70
0.9
0.71
0.639
1.56
0.13
4.5
1.33
33
DCDB bus-1
Bus coupler Bay Marshalling Kiosk
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
109
0.9
0.71
0.639
1.56
0.13
4.5
2.07
34
Feeder-1 Bay Marshalling Kiosk
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
109
0.9
0.71
0.639
1.56
0.13
4.5
2.07
35
Unit circuit breaker
220
220
1.00
XLPE-Cu
5Cx2.5A
28
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.63
36
Bus Isolator -1
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.62
37
Bus Isolator -2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
58
0.9
0.71
0.639
1.56
0.13
4.5
1.11
sheet 3 of 4
Sl. No. Rev
FROM EQUIPMENT
TO EQUIPMENT
DESIGNATION
DESIGNATION
LOAD
Voltage
utput Power
Amp
[V]
[W]
(In)
CABLE
TYPE
CABLE
RATED
LENGTH
No. OF SELECTED
CAPACITY RESISTANCE
RUNS CABLE SIZE
(m)
(/Km)
OF CABLE
mm2
(Iz)
Kt
Ks
Kg
REQUIRED PROTECTIVE
DEVICE
CAPACITY OF
Kd = (Kt x
Ks x Kg)
(In / Kd)
(Ir)
K2S2
(kA2s)
LETPERMISSIBLE
THROUGH
VOLTAGE
(kA2s)
DROP (Vr)
RUNNING
VOLTAGE
DROP (Vpr)
38
Line Isolator
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
50
0.9
0.71
0.639
1.56
0.13
4.5
39
DCDB bus-2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
109
0.9
0.71
0.639
1.56
0.13
4.5
0.95
2.07
40
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
109
0.9
0.71
0.639
1.56
0.13
4.5
2.07
41
220
220
1.00
XLPE-Cu
5Cx2.5A
28
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.63
42
Bus Isolator -1
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.62
43
Bus Isolator -2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
58
0.9
0.71
0.639
1.56
0.13
4.5
1.11
44
Line Isolator
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
50
0.9
0.71
0.639
1.56
0.13
4.5
0.95
45
DCDB bus-1
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
148
0.9
0.71
0.639
1.56
0.13
4.5
2.80
46
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
148
0.9
0.71
0.639
1.56
0.13
4.5
2.80
47
220
220
1.00
XLPE-Cu
5Cx2.5A
28
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.63
48
Bus Isolator -1
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.62
49
Bus Isolator -2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
58
0.9
0.71
0.639
1.56
0.13
4.5
1.11
50
Line Isolator
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
50
0.9
0.71
0.639
1.56
0.13
4.5
0.95
51
DCDB bus-2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
148
0.9
0.71
0.639
1.56
0.13
4.5
2.80
52
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
148
0.9
0.71
0.639
1.56
0.13
4.5
2.80
53
220
220
1.00
XLPE-Cu
5Cx2.5A
28
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.63
54
Bus Isolator -1
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
33
0.9
0.71
0.639
1.56
0.13
4.5
0.62
55
Bus Isolator -2
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
58
0.9
0.71
0.639
1.56
0.13
4.5
1.11
56
Line Isolator
220
220
1.00
XLPE-Cu
3Cx2.5A
30
9.5
50
0.9
0.71
0.639
1.56
0.13
4.5
0.95
sheet 4 of 4
ATTACHMENT 2 : CALCULATION SHEET (48V DC POWER CABLES)
FROM EQUIPMENT
TO EQUIPMENT
DESIGNATION
DESIGNATION
Voltage
[V]
Consumption/O
utput Power
[W]
LOAD CURRENT
IN Amp
CABLE
TYPE
RATED
CAPACITY OF
CABLE
CABLE
RESISTANCE
(/Km)
LENGTH
(m)
mm2
(Iz)
No. OF SELECTED
RUNS CABLE SIZE
(In)
Kt
Ks
Kg
Kd = (Kt x
Ks x Kg)
REQUIRED
CAPACITY OF
FEEDER (A)
PROTECTIVE
DEVICE RATING
(A)
(In / Kd)
(Ir)
K2S2
(kA2s)
PERMISSIBLE
LETVOLTAGE
THROUGH
DROP (Vr)
(kA2s)
RUNNING
VOLTAGE
DROP (Vpr)
BATTERY BANK 1
48 V BATTERY BANK
48 V BATTERY BANK
48 V BATTERY BANK
48 V DCDB
48 V DCDB
48 V DCDB
48
48
48
15
15
15
XLPE-AL
XLPE-AL
XLPE-AL
1
1
1
2Cx35
2Cx35
2Cx35
1.11
1.11
1.11
0.0783
0.0783
0.0783
20
20
20
0.9
0.9
0.9
1
1
1
0.71
0.71
0.71
0.639
0.639
0.639
23.47
23.47
23.47
80
80
80
10.82
10.82
10.82
0.51
0.51
0.51
0.92
0.92
0.92
0.68
0.68
0.68
48V DCDB
48 V DCDB
48 V DCDB
48 V DCDB
48 V DCDB
PLCC-1
PLCC-2
PLCC-3
PLCC4-Future
48
48
48
48
2.7
2.7
2.7
XLPE-AL
XLPE-AL
XLPE-AL
1
1
1
2Cx2.5
2Cx2.5
2Cx2.5
9.5
9.5
9.5
0.0985
0.0985
0.0985
16
16
16
0.9
0.9
0.9
1
1
1
0.71
0.71
0.71
0.639
0.639
0.639
4.23
4.23
4.23
16
16
16
10.82
10.82
10.82
0.099
0.099
0.099
1
1
1
0.84
0.84
0.84
sheet 1 of 1

HINLJR00BUA-ED00002a DC Cable Sizing Calculation

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TABLE DES MODIFICATIONS / MODIFICATIONS TABLE

2.1 REFERENCE STANDARDS

3.1 ENVIRONMENTAL CONDITIONS AND DESIGN CRITERIA

4.1 TYPE OF CABLE

CABLE SIZING METHOD

5.1 CURRENT CARRYING CAPACITY CRITERIA

CIRCUIT BREAKER SELECTION

ANNEXURE-I : CURRENT RATING, RESISTANCE & REACTANCE

ANNEUXRE-II : TEMPERATURE CORRECTION FACTOR

ANNEUXRE-III : GROUP RATING FACTORS

CALCULATION SHEETS (220V DC SYSTEM)

CALCULATION SHEETS (48V DC SYSTEM)

HINLJR20BUA-FD00001: 220 V DC System Single Line Diagram

HINLJR20BUA-FE00001: 220 V DC System Design memorandum

HINLJR20BUA-ED00001: 220 V DC System Power Balance

HINLJR20BUD-FD00001: 48 V DC System Single Line Diagram

HINLJR20BUD-FE00001: 48 V DC System Design memorandum

HINLJR20BUD-ED00001: 48 V DC System Power Balance

Electrical Instalations of Building Protection Against Over Current

Electrical Instalations of Building Selection and Erection of

Selection and Erection of Electrical Equipment Earthing

IEEE Std 241

Recommended Practice For Electrical Power System In Commercial

PVC insulated (heavy duty) electric cables specification: For working

Cross-Linked Polyetelene Insulated thermoplastic sheathed cables

Level III as per IS

Maximum ambient temperature

Minimum ambient temperature

Design ambient temperature for Electrical equipment

40% approx at 42oC

Zone II as per IS 1893

ELECTRICAL NETWORK DATA

220 V & 48V DC

..........................................................................Single / Multi core

Voltage grade .....................................................................1100V

..........................................................................Perforated Tray / Ladder Type

Single core cables ...............................................................Single layer laying with trefoil formation

CABLE SIZING METHOD

Current carrying capacity under normal operating condition

Current carrying capacity under short-circuit condition and

CURRENT CARRYING CAPACITY CRITERIA

rated current of cable (Annexure-I)

cable current carrying capacity de-rating factor

= correction factor for ambient temperature (Annexure-III)

Sun exposition factor which is

For cable screened from sun rays

For cable exposed to air with black sheath

For cable exposed to air with light colour sheath

Cable installation de-rating factor (Annexure-IV)

The maximum permanent current (In) of a feeder is given as

Nominal apparent power of the feeder

System voltage (220V for 220V DC System)

Size of the cable selected shall ensure

5.1.1 AMBIENT TEMPERATURE CORRECTION FACTOR

5.1.2 SUN EXPOSITION FACTOR

Sun exposition factor which is

For cable screened from sun rays

For cable exposed to air with black sheath

For cable exposed to air with light colour sheath

5.1.3 GROUPING FACTOR

SHORT CIRCUIT CRITERIA