ARAR 4.16kV CABLE SIZING REPORT

TCE CONSULTING ENGINEERS LIMITED
SHEET i OF i
30421007-3CL00013-P0B
4.16 kV MV CABLE
SIZING REPORT
SAUDI ELECTRICITY COMPANY

EASTERN OPERATING AREA
Dammam, Saudi Arabia
GENERATION EXPANSION OF ARAR POWER PLANT
(CONTRACT NO : 30421007/00)
DESIGN BASIS
FOR
4.16 kV MV CABLE SIZING
DOCUMENT NO : 30421007-3CL-00013-P0B
NOVEMBER 2004
ENGINEERING CONSULTANT
TCE CONSULTING ENGINEERS LIMITED
73/1, ST.MARK'S ROAD
BANGALORE 560001
INDIA
CONTRACTOR:
AL-TOUKHI COMPANY FOR INDUSTRY & TRADING
P.O.BOX 497, RIYADH 11411, KINGDOM OF SAUDI ARABIA
TEL.00966-1-4633660 : FAX.00966-1-4631150
P0B
01.11.2004
MP
SR
P0A
08.09.2004
MP
SR
REV NO. DATE
PREPARED BY
CHECKED BY
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SECTION :cover sheeet
CLEARED BY
APPROVED BY
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(CONTRACT NO : 30421007/00)
ARAR 4.16kV CABLE SIZING REPORT
DOCUMENT NO. 30421007-3CL-00013-P0B.
CONTENTS
SECTION
DESCRIPTION
1.0
SCOPE
2.0
STANDARDS & REFERENCES
3.0
GENERAL PARAMETERS
4.0
SIZING CRITERIA
5.0
CONCLUSION
6.0
CABLE SIZING REPORT SUMMARY
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SECTION :Index
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SECTION :Index
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ARAR 4.16 kV CABLE SIZING REPORT
1.0
DOCUMENT NO. 30421007-3CL-00013-P0B
SCOPE
Scope of this report is to calculate the 4.16kV Cable sizes(3.6/6kV Grade) for the following 3 cases.
CASE-1
4.16 kV Cable size (3.6/6kV Grade) from 4.16kV Station Transformer T 401 orT 402 to 4.16kV Station
Switchgear incoming breakers.
CASE-2
4.16 kV Cable size (3.6/6kV Grade) from 4.16kV Station Switchgear to Station Aux Transformer T201 or T202.
CASE-3
4.16 kV Cable size (3.6/6kV Grade) from 4.16kV Station Switchgear to Starting Motors GT#7 or GT#8
2.0
STANDARDS & REFERENCES
2.1
IEC 60986-short circuit sizing.
2.2
IEC 60364-5-523 Selection and erection of electrical equipment-Current Carrying capacities in wiring system.
2.3
SES-P-104.03 - Cable Selection -Engineering standards.
2.4
Key One Line Diagram for Arar Plant Drawing No: KA667481 REV-P0D
2.5
SAUDI CABLE COMPANY - Medium Voltage Cables Catalogues
3.0
GENERAL PARAMETERS
- Depth of Burried Cables
- Ground Temperature at a depth of 1 meter
- Average Thermal Soil resistivity
- Ambient air Temperature
- Short Circuit current
4.0
=
=
=
=
=
1 meter
35 Deg C
2 Deg C-m/w
50 Deg C
25 kA for 3 second for CASE#1
25 kA for 1 second for CASE#2 & CASE#3
SIZING CRITERIA
The Power Cable size shall be selected on the basis of :
- Short circuit Rating.
- Current Carrying Capacity.
- Permissible Voltage Drop.
4.1
SHORT CIRCUIT SIZING.

According to SES-P-104.03 Engineering standards Cl No:4.9.6 the minimum cable cross section may be
calculated with the formula:
142 x S
I =
t
Where,
I = Maximum Allowable conductor Short Circuit Current in Amps
t = Duration of Short circuits in seconds
S = Cross Sectional Area of Current Carrying conductor in Sqmm
K = Temperature co-efficient of conductor resistance. = 142 for copper XLPE
therefore,
Ix t
S =
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SECTION :Notes and Sizing Cal
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S

142
FOR CASE-1
25000 x 3
142
304.930
Sqmm
Minimum nearest cable size is 400 Sqmm (Refer SAUDI CABLE COMPANY)
However,As per the Cl.No. 3.03-13 of PTS-1022, page 40 of 336, the size of cable from Station
Transformer to Station Switchgear is selected as 1C x 630 Sqmm/Phase Cu, XLPE Unarmoured.
FOR CASE-2
S
25000 x 1
142
176.056
Sqmm
Minimum nearest cable size 185 Sqmm (Refer SAUDI CABLE COMPANY)
However, as per the Cl.No. 3.03-13 of PTS-1022, page 40 of 336, the size of cable from Station
Switchgear to Station Aux Transformers T201or T202 is selected as 1C x 630 Sqmm/Phase Cu, XLPE
unarmoured.
FOR CASE-3
S
25000 x 1
142
176.056
Sqmm
Minimum nearest cable size 185 Sqmm (Refer SAUDI CABLE COMPANY)
However, as per the Cl.No. 3.03-14 of PTS-1022, page 40 of 336, the size of cable from Station
Switchgear to Starting Motor is selected as 3C x185 Sqmm, Cu, XLPE Unarmoured.
4.2
CURRENT CARRYING CAPACITY

CASE-1 from 4.16kV Station Transformer T 401 orT 402 to 4.16kV Station Switchgear incoming
breakers.
The total load current to be
carried by 4.16kV cable to
Station Switchgears
7.5 MVA
=
3 x 4.16 kV
= 1040.92Amps
CASE-2 from 4.16kV Station Switchgear to Station Aux Transformer T201 or T202.
Station Aux Transformer
T201or T202
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3 MVA
=
= 416.37 Amps
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Station Aux Transformer
T201or T202

=
= 416.37 Amps
3 x 4.16 kV
According to SAUDI CABLE COMPANY Catalogues for Medium Voltage Cable System,the nominal
current carrying capacities are,
FOR CASE-1 & case 2
Current Carrying capacity
Laying Conditions(in duct)
in Amps for 1C x 630
Sqmm
Laid directly in ground or duct ways, Ground
temp.in flat formation 30 DegC and Thermal
665
resistivity of soil = 1.2K m/W, depth of laying =
0.8m
temp.in trefoil formation 30 DegC and Thermal
resistivity of soil = 1.2K m/W, depth of laying =
0.8m
720

Sqmm
Laying Conditions (in Air)

Laid in Air (tray),in flat formation Ambient
Temperature 40 Deg C
980
Laid in Air (Tray), in trefoil formation Ambient

Temperature 40 Deg C
960
FOR CASE-1 & CASE-2

Derating factor Kd for 1C x 630 Sqmm Cable Laid in Duct ways :(for both Flat/trefoil formation)
-
Ground Temperature 35 DegC

K1
=
0.95
Thermal Resistivity of soil 2.0DegC m/W K2
=
0.84
Depth of Laying 1m
K3
=
0.98
Group Rating Factor
K4
=
0.80
-according to:
- installation system = spacing between two ducts(center line to center line) equl 0.3m
- No of ducts in ground = 3
Derating Factor Kd
= K1 x K2 x K3 x K4
Kd = 0.6256
Derating factor Ka for 1C x 630 Sqmm Cable installed in free air:(for both Flat/trefoil formation)
- ambient Air Temperature 50 DegC
K5
- Laying on Cable Tray(in touching form)
K6
according to:
- installation system in three phase circuits
- No of trays = 3
Derating Factor Ka
Ka
=
=
=
=
0.89
0.86
K5 x K6
0.7654
According to the above, the maximum current carrying capacity of the selected 1C x 630Sqmm cable
as follows
Maximum current carrying capacity of 1C x 630Sqmm Cable Laid in Duct ways(after considering
derating factor)
Laying cable in flat formation, current
275167996.xls
665 x Kd =
416.05
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Laying cable in trefoil formation, current
720 x Kd =
450.46
Maximum current carrying capacity of 1C x 630Sqmm cable Laid in Air(Cable Tray)

(after considering derating factor)
Laying cable in flat formation, current
Laying cable in trefoil formation, current
=
=
980 x Ka =
960 x Ka =
750.09
734.78
FOR CASE-1 (From Station Transformer to Staion Switchgear incoming breakers)

As per above calculation, 3-Nos of 1C x 630 Sqmm/Phase cable can carry the required load current
of 1040.96Amps under all site conditions when cable laid in duct ways.
As per above calculation, 2-Nos of 1C x 630 Sqmm/Phase cable can carry the required load current
of 1040.96Amps under all site conditions when cable laid in Air(Cable Tray)
FOR CASE-2 (From Station Switchgear to Station Aux Transformer)
Also as per above calculation,1C x 630 Sqmm/Phase cable can carry the required load current
of 416.37 Amps under all site conditions.
CASE-3 from 4.16kV Station Switchgear to Starting Motor GT#7 or GT#8

starting motors
596.8kW
=
3x4.16x0.85x0.95
The cable selected as 3C x 185 Sqmm size)

Laying Conditions(in duct)
temp.30 Deg C and Thermal resistivity of soil =
1.2K-m/W, depth of laying = 0.8m
Laying Conditions (in Air)

Laid in Air (tray),in Ambient Temperature 40 Deg
C
= 102.575 Amps

Sqmm
380

Sqmm
410
The following Derating factors have been considered as per SAUDI CABLE COMPANY Catalogues
for the site conditions specified:
Derating factor Kd for 3C x185 Sqmm Cable Laid in Duct ways :
- Ground Temperature 35 DegC
K1
=
0.95
- Thermal Resistivity of soil 2.0Deg C-m/W K2
=
0.87
- Depth of Laying 1m
K3
=
0.99
- Group Rating Factor
K4
=
0.90
-according to:
- installation system = spacing between two adjacent (center line to center line) ducts equal 0.3m
- No of ducts in ground = 2
Derating Factor Kd
= K1 x K2 x K3 x K4
Kd = 0.7364
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Derating factor Ka for 3C x185 Sqmm Cable installed in free air:

- ambient Air Temperature 50 DegC
K5
- Laying on Cable Tray(in touching form)
K6
according to:
- installation system in three phase circuits
- No of trays = 3
Derating Factor Ka
Ka
=
=
=
=
0.89
0.7
K5 x K6
0.6230
According to the above, the maximum current carrying capacity of the selected 3C x 185 Sqmm cable
as follows
Maximum current carrying capacity of 3C x 185 sqmm Cable Laid in Duct ways(after considering
derating factor)
Laying cable in duct, current
380 x Kd =
279.84
Maximum current carrying capacity of 3C x 185 Sqmm Cable Laid in Air(Cable Tray)
(after considering derating factor)
Laying cable in Cable Tray, current
410 x Ka =
255.43
From 4.16kV Station Switchgear to Starting motor

As per above calculation,3C x 185 Sqmm cable size can carry the required load current
of 102.575 Amps under all site conditions.
4.3
VOLTAGE DROP SIZING

The Voltage drop check is calculated as follows :
=
V%
3 x(RCOS + XSIN) x I x L x 100 /Un for three phase system
Where,
FOR CASE-1
FOR CASE-2
1C x 630
1C x 630
COS
=
Power Factor
= 0.8
0.8
SIN
=
= 0.6
0.6
Full load Current in A =
I
=
520.46
416.37
L
=
Length in Km
= 0.05
0.075
Un
=
Cable Voltage in V = 4160
4160
R
=
0.0434
Resistance /Km = 0.0434
X
=
0.11
Reactance /Km = 0.11
The Voltage Drop for CASE-1 from 4.16kV Station Transformer T 401 orT 402 to 4.16kV Station
Switchgear incoming breakers.
V%
=
0.109 % Volts
Hence, Voltage drop is within the limits.
which is < 5%
The Voltage Drop for CASE-2 from 4.16kV Station Switchgear to Station Aux
Transformer T201 or T202.
=
0.131 % Volts
V%
Hence, Voltage drop is within the limits.
which is < 5%
FOR CASE-3 from 4.16kV Station Switchgear to Starting Motor GT#7 or GT#8
The Voltage drop check is calculated as follows:
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During starting
=
V%
Where,
Un
=
3 (I1Z1L1 + I2Z2L2)x100/Un
Voltage in V
4160
I1 is the current of Station Transformer

Secondary side cable
I1 = I2 + Base load on 4.16kV SWGR
I2 is the current of Station SWGR to Motor

Cable during starting condition.
I2 = 6 times the motor full load current =6x102.575 = 615.45 A
Base Load on 4.16kV SWGR
= 1941.5kVA
Base Load in Amps
= 269.46
Therefore, 615.45 + 296.46
I1 =
884.91 Amps
I2 =
615.45 Amps
Refer Cl.No.5.2.2 ,page 6 of 8 of Doc

No:30421007-3CL-00006-P0A 33/4.16kV
Station Transformer sizing Report
Z1 is Impedance of Station Transformer

Secondary side cable ie., 1C x 630 Sqmm
Z1 = R1COS1 + X1SIN1
Z2 is Impedance of Station Swgr to Motor

cable. ie., 3C x 185 Sqmm
Z2 = R2COS2 + X2SIN2
Power Factor for starting COS =

SIN =
1C x 630 Sqmm Cable Length in km
R1
=
Resistance /Km
X1
Reactance /Km
3C x 185 Sqmm Cable Length in km

R2
=
Resistance /Km
X2
Reactance /Km
L1 =
0.2
0.98
0.05
0.0434
0.11
L2 =
0.2
0.129
0.1
Z1 =
0.12
Z2 =
0.12
The Voltage drop in cable from secondary of station Transformer to 4.16kV Motor terminal during starting
condition of 4.16kV Motor
V%
0.849 % Volts
During Running
3 (I1Z1L1 + I2Z2L2)x100/Un
=
V%
Where,
I1 is the current in Station Transformer
I1 = I2 + Base load on 4.16kV SWGR
Secondary side cable
I2 is the current in Station SWGR to Motor
I2 = Motor full load current = 102.575amps
Cable during running
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Power Factor for Running COS =

SIN =
0.85
0.53
I1 =
372.035
I2 =
102.575
Z1 =
0.09
Z2 =
0.16
The Voltage drop during running condition of 4.16kV Motor

V%
5.0
0.212 % Volts
CONCLUSION
CASE-1
From Station Transformers T 401 or T 402 to Station switchgear incoming breakers
3/6 kV Grade, XLPE insulated, Copper Conductor of size 3Nos-1C x 630 Sqmm/Phase,
Unarmoured cable has been selected based on the above calculations when cable laid in duct ways.
From Station Transformers T 401 or T 402 to Station switchgear incoming breakers
3/6 kV Grade, XLPE insulated, Copper Conductor of size 2Nos-1C x 630 Sqmm/Phase,
Unarmoured cable has been selected based on the above calculations when cable laid in Air (Cable Tray).
CASE-2
From Station Switchgear to Station Aux Transformers T 201 or T 202
3/6 kV Grade, XLPE insulated, Copper Conductor of size 1C x 630 Sqmm/Phase, Unarmoured
cable has been selected based on the above calculations.
CASE-3
From 4.16kV Station Switchgear to Starting motors GT#7 & GT#8
3.6/6 kV Grade, XLPE insulated, Copper Conductor of size 3C x 185 Sqmm, Unarmoured
cable has been selected based on the above calculations.
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V Grade) for the following 3 cases.
mer T 401 orT 402 to 4.16kV Station
ear to Station Aux Transformer T201 or T202.
ear to Starting Motors GT#7 or GT#8
urrent Carrying capacities in wiring system.
V-P0D
as per Cl.No.4.01.1 page 70 of

336, Cl.No.4.01.2 page 71 of
336 of PTS - 1022
nd for CASE#1
nd for CASE#2 & CASE#3
e minimum cable cross section may be
t Circuit Current in Amps
rying conductor in Sqmm

or resistance. = 142 for copper XLPE
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the size of cable from Station

/Phase Cu, XLPE Unarmoured.

as 1C x 630 Sqmm/Phase Cu, XLPE

XLPE Unarmoured.
6kV Station Switchgear incoming
former T201 or T202.
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Voltage Cable System,the nominal
for both Flat/trefoil formation)
center line) equl 0.3m
(for both Flat/trefoil formation)
as per IEC 60364-5-523

table 52-E5
the selected 1C x 630Sqmm cable
Laid in Duct ways(after considering
Amps
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Amps
Laid in Air(Cable Tray)
Amps
Amps
oming breakers)
can carry the required load current
can carry the required load current
arry the required load current
DI CABLE COMPANY Catalogues
e to center line) ducts equal 0.3m
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as per IEC 60364-5-523

table 52-E4
the selected 3C x 185 Sqmm cable
Laid in Duct ways(after considering
Amps
Laid in Air(Cable Tray)
Amps
required load current
three phase system

Note:
For Case-1:
The full load current for
2Runs of 1Cx630Sqmm/phase
is 1040.92A. Hence for 1Run
of 1Cx630Sqmm/phase is
considered as 1040.92/2 =
520.46Amps
r T 401 orT 402 to 4.16kV Station
r to Station Aux
or GT#7 or GT#8
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n 4.16kV SWGR
or full load current =6x102.575 = 615.45 A

Refer Cl.No.5.2.2 ,page 6 of 8 of Doc
No:30421007-3CL-00006-P0A 33/4.16kV
Station Transformer sizing Report
to 4.16kV Motor terminal during starting
n 4.16kV SWGR
urrent = 102.575amps
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ncoming breakers
s-1C x 630 Sqmm/Phase,
lations when cable laid in duct ways.
ncoming breakers
s-1C x 630 Sqmm/Phase,
lations when cable laid in Air (Cable Tray).
630 Sqmm/Phase, Unarmoured
x 185 Sqmm, Unarmoured
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6.0 CABLE SIZING REPORT SUMMARY
ARAR 4.16kV CABLE SIZING REPORT

SL
NO.
FEEDER DESCRIPTION
LOAD
VOLTAGE
kVA / kW
VOLTS
FULL
LOAD
CURRENT CARRYING CAPACITY OF CABLE (SINGLE
CABLE SIZE SELECTED
CURRENT
RUN)
IFL
AMPS
SQ.MM
IN DUCT
BANKS
IN AIR
DERATING FACTOR
CURRENT CARRYING CAPACITY OF

CABLE AFTER DERATING FACTOR (SINGLE RUN)
CABLE LAID IN AIR(CABLE CABLE LAID IN DUCT CABLE LAID IN AIRCABLE LAID IN DUCT
CABLE LAID IN AIR(CABLE
BANKS
CABLE TRAYS
TRAY)
BANKS
TRAY)
(IN BOTH
(IN
FLAT/TREFOIL
BOTH FLAT/TREFOIL
IN FLAT
IN TREFOIL
IN FLAT
IN TREFOIL
IN FLAT
IN TREFOIL
IN FLAT
IN TREFOIL
FORMATION)
FORMATION)
FORMATION FORMATION FORMATION FORMATION
FORMATION FORMATION FORMATION FORMATION
CABLE LAID IN DUCT
BANKS
LENGTH
OF
CABLE
% VOLTAGE
DROP
KM
CASE-1
STATION TRANSFORMER T401 or
T402 TO STATION SWITCHGEAR
INCOMING BREAKERS (Load in
kVA)
7500
4160
1040.93
3 RUNS OF 2 RUNS OF
1C X
1C X
630 sqmm / 630 sqmm /
phase
phase
665.00
720.00
980.00
960.00
0.6256
0.7654
416.02
450.43
750.09
734.78
0.05
0.109
CASE-2
STATION SWITCHGEAR TO LV
STATION AUX TRANSFORMER
T201or T202 (Load in kVA)
3000
4160
416.37
I RUN OF
1C X 630
sqmm /
phase
665.00
720.00
980.00
960.00
0.6256
0.7654
416.02
450.43
750.09
734.78
0.075
0.131
CASE-3
STATION SWITCHGEAR TO
STARTING MOTORS GT#7 or
GT#8 (Load in kW)
596.8
4160
102.58
1 RUN OF 1 RUN OF
3C X 185
3C X 185
0.7364
0.6230
275167996.xls
SECTION :Cable Sizing Report Summary
I RUN OF
1C X 630
sqmm /
phase
380.00
410.00
279.83
255.43
0.2
for starting = 0.85

for running
= 0.21
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