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1.0
INTRODUCTION
2.0
A)
B)
C)
D)
E)
F)
G)
GENERAL GUIDELINES
Voltage grade of cable
Cable insulation
Conductor material
Armouring
Number of cores
Screening / Shielding
Single run versus Multiple runs
A)
B)
C)
D)
E)
F)
3.0
4.0
5.0
6.0
7.0
ANNEXURES
Annexure I : Current and Fault current carrying capacity of cables
Annexure II : Derating factors for installation & laying methods
A)
B)
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Description :
Prepared :
Reviewed:
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1.0
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Introduction
Generally in any of electrical auxiliary system, for each feeder or motor circuit application,
a suitable power cable with requisite specifications such as conductor size, type of
armouring etc., has to be designed for satisfactory operation during normal and abnormal
operating conditions. These design guidelines are intended to simplify the various needs
for selection of optimum size and appropriate type of cable for the specified applications.
2.0
General Guidelines
While selecting a cable the following guidelines shall be used for specifying the type of
cable etc.
A) Voltage grade of cable: Based on System voltage and system earthing the voltage
grade of cable can be selected from the following table:
System Voltage kV
11
6.35/11 kV
11/11 kV
6.6
3.8/6.6 kV
6.35/11 kV OR 6.6/6.6 kV
3.3
1.9/3.3 kV
3.8/6.6 kV OR 3.3/3.3 kV
0.415
650/1100 V (IS) OR
600/1000 V(IEC)
1.1/1.1 kV
Max.
temp. under Max. temp under S/C
normal operations
conditions
70 Deg C
90 Deg C
160 Deg C
250 Deg C
LV(1.1kV & less) - Power & control cables - PVC/XLPE insulated cables
MV (Above 1.1kV)- Power cables - XLPE insulated cables
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Copper
Aluminium
:
:
Generally the
IS 1554 specifies the following for selection between solid / strandard conductors
Table - B
Cu. conductor Aluminum conductor
(sq.mm)
(sq.mm)
Type of conductor
1.5 - 6
10 and above
Solid
Solid / Strandard
Strandard
1.5
2.5 - 10
16 and above
For multicore cables (as per IS 1554), where calculated diameter below armouring
does not exceed 13mm armouring shall be of galvanised round steel wire, and for
cables where calculated diameter below armouring exceed 13mm armouring shall be
of galvanised round steel wire or galvanised steel strips.
Single core cables are recommended for incomer feeders from transformer to
switchgear and for higher current rating feeders irrespective of voltage level. This is
being followed in view of the condition that for larger current ratings 3 core cables will
be physically larger and huge for installation. For various voltage levels ,
recommended standard sizes have been furnished in clause 6.0.
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For fuse protected feeders, multicore cables are recommended. Wherever 3 phase,
neutral is required (i.e.) switch fuse feeders in LV system 4 core/3.5 core cables are to
be adopted. For all L.V. motor feeders 4 core/3.5 core cables will be adopted wherein 3
cores are used for phases and 4th core is for earthing.
F) Screening/Shielding :
Normally screening is provided over the conductor and insulation for HV cables. In case of
insulation screening it consists basically of a semiconducting screen combined with
metallic screen. Whereas only semiconducting screen is provided for the conductor.
Shielding /screening basically helps in :
To have uniform distribution of voltage stress between conductor surface and outer
surface of insulation.
To limit electromagnetic field beyond the shield to a low value.
To minimise voltage stress on conductor surface.
To reduce shock hazards when shields are properly grounded by suitable means at
both the cable ends
Critically, the following technical aspects to be satisfied on selecting cable for particular
application.
A) Current rating for continuous operation
B) Fault current withstand capability
C) Voltage Regulation (Voltage Drop)
D) Sheath Voltage check ( for 1 core cables)
E) Type of cable installation (laid in air , buried etc.)and
Thermal conditions (ambient temp., soil conditions)
A)
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The Major factors responsible for deciding the continuous current rating of a cable can be
broadly classified as following:
1) Cable selection includes
aa) Conductor Material (either copper or aluminum)
bb) Max. temperature for conductor
The following table gives the maximum conductor temperature for
adopted for cables
Cable insulation
PVC
XLPE
70 Deg C
90 Deg C
under
generally
S/C
160 Deg C
250 Deg C
Note: The current carrying capacity given in the annexure I for various cables are based
on the above Maximum temperatures.
B) Fault Current / Short circuit Withstand Capacity of the cable
Depending upon the fault current magnitude and duration, the minimum conductor size
shall be arrived using the formula:
Ik =
A
k1*k2*t
Where,
Ik = Fault current in kA
k2=constant (depending upon the temperature before and after short circuit)
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1)
Value of k1 & :
Conductor Material
Aluminium
Copper (screen)
Galvanised steel (armour)
2)
Value of k1
6.76
4.41
12.8
Value of T1 & T2 :
Type of material
Armour for PVC Cables
Conductor with PVC insulation
Screen/ armour for XLPE cables
Conductor with XLPE cables
3)
value of
228
234.5
202
T1 (deg. C)
60
70
80
90
T2 (deg C)
N.A.
160
200
250
Type of cable
k1
T1
70
T2
160
k2
1.94
Ik (kA)
Ik = 0.076*A
t
90
250
1.56
Ik =
0.094*A
t
Copper screens
4.41 234.5
80
200
1.76
Ik =
0.0128*A
t
12.8 202
80
200
1.7
Ik =
0.046*A
t
80
200
1.74
Ik =
0.0848*A
t
60
200
1.528
Ik =
0.051*A
t
60
200
1.588
Ik =
0.093*A
t
Aluminium
XLPE
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4)
Recommendations for short circuit current density of short circuit current duration
(max.) of 120 msec in breaker protected circuits:
Type of cable
Aluminium conductor, PVC
Aluminium conductor, XLPE
Copper Screen
Aluminium armour, PVC
Aluminium armour, XLPE
Galvanised steel armour, PVC
Galvanised steel armour, XLPE
5)
The duration of fault current can be decided based on the type of protection
provided for the particular feeder.This is because fault clearing time of protective device
determines the duration of short circuit current, the cable has to withstand. The
recommended values are :
Protective
Device
Circuit Breaker
Fuses
Note: The fault current withstand capability of various sizes of cables are also included in
the annexure III for a duration of 1 sec.
Based on the type of faults and overloading, further classifications and analysis shall be
made, if required. (Ref : CEGB Modern power station practise Vol- D chapter - 6)
C)
Due to impedance of the conductor, there is voltage drop in the cable between sending
end and the receiving end. All electrical equipments in the plant are designated to operate
within specified limits of voltage regulation during normal running and starting conditions.
The permissible voltage drop in Cable portion shall be restricted to the following
generally:
- During normal running conditions :
3% Voltage drop
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- During starting
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However the customer requirements needs to be checked for project specific application.
1)
Where,
R = AC resistance per unit length at Max. operating temp (70 deg for PVC, 90 deg for
XLPE) in
Note :
In case more than single run of cable is used, then it is assumed that total current is
equally distributed among the runs
When large motors are used in the system, motor locked rotor current can cause
sustained reduction in voltage at motor terminals as well as at the bus. Therefore
motor starting current and starting power factor should be taken into account for
voltage drop calculation
2)
For the given conditions and selected cable, the maximum length of cable for that
application shall be calculated for both the normal/running and starting conditions by using
the following formula
Lmax = Length of Cable x Voltage drop (permissible %)
Actual Voltage drop %
Lmax = Min (Lmax_start, Lmax_run)
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The calculated value of Lmax should be more than the actual cable route length, thereby
ensuring that the cable is adequately protected against earth faults and the voltage
regulation is within permissible limits. In case it comes out to be less than actual cable
route length, then select the next higher conductor size.
D) Sheath Voltage check ( for 1 core cables):
For single Core cables, metallic screen losses and armour losses (which occur due to
circulating currents), can be reduced by bonding the armour to earth at one end. This will
however induce certain voltage at open end. This is referred as Sheath Voltage.
The maximum permissible sheath voltages are as under:
volts / metre
ii) Sheath voltage during fault conditions can be directly arrived as a proportionate of Vfl.
Vsc = Vfl * Isc / Ifl
Where,
Note:
For multicore cables, it can be bonded at both the ends and no derating in the cable
need to be considered.
In case of single core cable and bonded at both the ends, manufacturers
recommended derating factors need to be considered.
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Various installation and laying methods will also derate the cable current carrying capacity.
These factors are given in the annexure.II ( As per manufacturers recommendations.)
4.0
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In case customer requirement is there for this type of cables following needs to be taken
care.
These cables are generally used for certain emergency /essential auxiliaries/critical areas
so as to ensure that these auxiliaries work satisfactorily under severe fire conditions.
Fire survival cables are recommended generally for the following areas :(As per CEA
guidelines)
Exact areas to be adopted needs to be checked from project to project basis.These cables
are generally designed to meet the requirements of IEC 331 flame retardent
characteristics of 750 deg c for 3 hours.
5.0
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Not available
Available
Calculate Voltage drop
(normal & starting)
Check availabilty of cable
size in project cable list
Is voltage drop within
Permissible limits?
NO
YES
Select the cable.
Find Max. permissible length.
YES
NO
6.0
STANDARD
PROJECTS
RECOMMENDED
CABLES
SIZES
ADOPTED
FOR
ABB
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3C X 300 SQ. mm
1C X 400 SQ. mm
1C X 630 SQ. mm
6.6 kV, XLPE, AL. conductor, (Armoured/Unarmoured)
3C X 185 SQ. mm
3CX 240 SQ. mm
1CX 400 SQ. mm
3.3 kV ,XLPE AL conductor (Armoured/unarmoured)
3CX50 Sq mm
3CX95 Sqmm
3CX150 Sqmm
1CX240 Sqmm
1CX400 Sqmm
1CX500Sqmm
1.1 kV (LT power cables), PVC, AL. conductor, (Armoured/Unarmoured)
2C X 16 SQ. mm
2C X 35 SQ. mm
2C X 70 SQ. mm
2C X 120 SQ. mm
4C X 16 SQ mm
3.5C X 35 SQ. mm
3.5C X 70 SQ. mm
3.5C X 120 SQ. mm
3.5 X 185 SQ. mm
3.5C X 240 SQ. mm
1C X 400 SQ. mm
1C X 800 SQ. mm
1.1 kV (LT power cables), PVC, CU. conductor, (Armoured/Unarmoured)
4C X 4 SQ. mm
4C X 6 SQ. mm
1.1 kV (LT control cables), PVC, CU. conductor, (Armoured/Unarmoured)
3C X 1.5 SQ. mm
4C X 1.5 SQ. mm
7C X 1.5 SQ. mm
12C X 1.5 SQ. mm
19C X 1.5 SQ. mm
2C X 2.5 SQ. mm
3C X 2.5 SQ. mm
4C X 2.5 SQ. m m
5C X 2.5 SQ. mm
7C X 2.5 SQ. mm
12C X 2.5 SQ. mm
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