Cables DM Vindh1

NATIONAL THERMAL POWER CORPORATION LTD.
2 x 500MW VINDHYACHAL STPP STAGE-III
DESIGN CALCULATIONS FOR CABLE SIZING AND SELECTION
NTPC DOC. NO. 2240-108-23PE-PVE-K-026
BHEL DOC. NO. PE-DC-209-507-E003
REVISION 0
BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR
PROJECT ENGINEERING MANAGEMENT
NEW DELHI, INDIA
Design Calculations For Cable Sizing & Selection Doc. No. PE-DC-209-507-E003
Rev No. 0
2 x 500 MW Vindhyachal STPP, Stage-III
January 21, 2004
INDEX:
S. NO. CONTENTS NO. OF SHEETS
1 DESIGN CALCULATIONS 14
2 ANNEXURE-A: SELECTION TABLE FOR CABLE SIZES
TABLE-A: CABLE SELECTION TABLE FOR 11 kV SYSTEM 4
TABLE-B1: CABLE SELECTION TABLE FOR 3.3 kV SYSTEM 2

TABLE-B2: CABLE SELECTION TABLE FOR 3.3 kV (VFD SYSTEM) 1
TABLE-C: CABLE SELECTION TABLE FOR 415 V SUPPLY FEEDERS: CABLES LAID 1
IN AIR
TABLE-D: CABLE SELECTION TABLE FOR 415 V SUPPLY FEEDERS: CABLES LAID 1
IN TRENCH
TABLE-E: CABLE SELECTION TABLE FOR 415 V MOTOR FEEDERS: CABLES LAID 1
IN AIR
TABLE-F: CABLE SELECTION TABLE FOR 415 V MOTOR FEEDERS: CABLES LAID
IN TRENCH
TABLE-G: CABLE SELECTION TABLE FOR 240 V AC SUPPLY SYSTEM: CABLES 1

LAID IN AIR
TABLE-H: CABLE SELECTION TABLE FOR 240 V AC SUPPLY SYSTEM: CABLES 1

LAID IN TRENCH
TABLE-I: CABLE SELECTION TABLE FOR 220 V DC SYSTEM: 1

CABLES LAID IN AIR
3 ANNEXURE-B: CABLE DATA 21
4 ANNEXURE-C: SUMMARY SHEET (CABLE SIZES FINALISED FOR THE PROJECT) 1

Doc. No.
Design Calculations For Cable Sizing & Selection
PE-DC-209-507-E003
Rev No. 0
January 21, 2004
1.0 CONTENTS
This document covers the following:

(a) Scope
(b) Type of cables selected
(c) Basis for design calculations for cable sizing
(d) Sample calculations
(e) Selection Tables For Cable Sizes
(f) Cable Data
2.0 SCOPE
2.1 This document is intended to cover the selection and/or sizing calculations of 11kV, 3.3 kV, 415V AC, 240V AC
and 220V DC power cables and control cables required for the interconnection of electrical equipment.
2.2 The details of cables for the following are excluded from the scope of this document:
a) Steam Generator integral cabling
b) Turbine & Generator integral cabling
c) ESP integral cabling
d) ID Fan VFD integral cabling
e) Switchyard cabling
f) Auxiliary plants in the scope of NTPC
g) 24 V DC system power cables.
Separate documentation shall be submitted separately for the above.
2.3 The details of screened control cables shall be covered in C& I documentation such as wiring diagrams/ block
cable diagrams, which will be submitted separately.
3.0 TYPE OF CABLES SELECTED
3.1 The following type of cables are selected in line with NTPC specification Vol-II, Part-B, Section:E18.
a) 11kV & 3.3 kV Power Cables

The cables for 11 kV & 3.3 kV system are 1-core or 3-core unearthed grade with circular stranded aluminium
conductor, conductor screening, crosslinked polyethylene (XLPE) insulation, insulation screening, core
identification by colour coding, distinct extruded inner sheath of PVC type ST2 material for all armoured and
multicore unarmoured cables only (inner sheath not envisaged for single core unarmoured cables), aluminium
wire armour for single core cable and GS formed wire armour as per IS: 3975 for multicore cables (armour
provided for directly buried cables only) and extruded PVC Type ST2 outer sheath with FRLS properties,
generally conforming to IS:7098 (Part-2). The conductor screen and insulation screen shall both be extruded
semi-conducting compound and shall be applied along with XLPE insulation in a single operation by triple
extrusion process. Method of curing shall be "Dry curing/ gas curing".
Maximum conductor temperature for normal operation is 90 deg. C and for short circuit conditions, 250 deg. C.
Minimum conductor size is 150 sq. mm.
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b) 1.1 kV Power Cables (sizes 150 sq. mm. and above)
Power cables for the 415 V AC, 240V AC system and 220V DC system are 1-core, 3-core and 3-1/2-core, 1100
V earthed grade with stranded aluminium conductor, crosslinked polyethylene (XLPE) insulation, core
identification by colour coding, distinct extruded inner sheath of PVC type ST2 material for all armoured cables
and multicore unarmoured cables only (inner sheath not envisaged for single core unarmoured cables), Al wire
armour for single core cables and GS formed wire armour as per IS: 3975 for multicore cables (armour provided
for directly buried cables only) and extruded PVC type ST2 outer sheath with FRLS properties, generally
conforming to IS:7098 (Part-1).
Minimum conductor cross section is 150 sq. mm.
c) 1.1 kV Power Cables (below 150 sq. mm.)
Power cables for the 415 V AC, 240V AC and 220V DC systems are 2-core, 3-core, 31/2-core and 4-core 650/
1100 V earthed grade with stranded aluminium/copper conductor, PVC Type-A insulation, core identification by
colour coding, distinct extruded inner sheath of PVC Type ST1 material (for armoured cables and multicore
unarmoured cables only), aluminium wire armour for single core cable and GS formed wire armour as per IS:
3975 for multicore cables (armour provided for directly buried cables only) and extruded PVC Type ST1 outer
sheath with FRLS properties, generally conforming to IS:1554 (Part-1).
The minimum conductor cross section is 2.5 sq. mm. for copper and 6 sq. mm. for aluminium conductor.
d) Control cables
Control cables are of 650/ 1100 V earthed grade with stranded plain annealed copper conductor, PVC Type-A
insulation, core identification by colour coding (upto five cores)/ number marking (more than five cores), distinct
extruded inner sheath of PVC Type ST1 material, GS formed wire armour as per IS: 3975 (armour provided for
directly buried cables only) and extruded PVC type ST1 outer sheath with FRLS properties, generally
conforming to IS:1554 (Part-1).
The minimum conductor cross section is 1.5 sq. mm.
3.2 Standards applicable:
a) IS:7098 Part-2 Specification for Cross Linked Polyethylene Insulated PVC Sheathed Cables (for working
voltages from 3.3 kV up to and including 33 kV).
b) IS:7098 Part-1 Specification for Cross Linked Polyethylene Insulated PVC Sheathed Cables (for working
voltages up to and including 1100 V).
c) IS:1554 Part-1 Specification for PVC insulated (Heavy Duty) Electric Cables (for working voltages up to
and including 1100 V).
4.0 BASIS FOR DESIGN CALCULATIONS FOR CABLE SIZING
4.1 DESIGN CONSIDERATIONS: POWER CABLES
4.1.1 In general, Power Cables are sized to satisfy the following three criteria:
(a) Short circuit current withstand capacity for applicable fault current and duration.
(b) Full load current carrying capacity under installation conditions (i.e. with suitable derating factors to cover site
conditions such as ambient and ground temperatures, grouping and soil resistivity and cable laying
configuration).
(c) Maximum voltage drop limits under steady state / transient state as applicable.
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4.1.2 The normal current ratings for the feeders are considered as under:
(a) 11 kV Transformer feeders:

Current ratings corresponding to MVA rating of the transformer.
(b) 11 kV Motor feeders:

Current ratings corresponding to the full load current of motor.
Power factor (except for CW pump motor) and efficiency for 11 kV motors are considered as below :
Cosφ= 0.9
Efficiency= 0.9
Power Factor for CW pump motor= 0.75
(c) 3.3 kV Transformer feeders:

Current ratings corresponding to MVA rating of the transformer.
(d) 3.3 kV Motor feeders:
Current ratings corresponding to the full load current of motor.
Power factor and efficiency for 3.3 kV motors are considered as below :
Cosφ= 0.85
Efficiency= 0.9
(e) 3.3 kV feeders (VFD system)
Efficiency for ID fan= 0.85

Power Factor for ID fan= 0.9
The current ratings for other feeders for VFD system are based on recommendations provided by VFD system
supplier.
(f) 415 V Supply feeders:

Presently considered as 90 % of the standard busbar rating, since LVAC system design is in progress.
However, the actual cable sizes will be deduced on the basis of the actual current loading of each switchboard /
MCC / ACDB.
The neutral cable is sized on the basis of half the uprated load current.
Power factor for 415 V supply feeders are considered as below :
Cosφ= 0.85
Sinφ= 0.53
(g) 415 V Motor feeders:

Normal current ratings for motor feeders are taken as the full load current corresponding to the highest rated
motor of the group. For transient voltage drop consideration, the starting current is taken as 7.2 times the full
load current.
Power factor x efficiency for 415 V motors under steady state conditions are considered as below :
Up to 1.0 kW = 0.7 x 0.74= 0.52
1.1 to 40 kW= 0.84 x 0.84= 0.71
40.1 to 200 kW= 0.85 x 0.95= 0.81
Under transient conditions,
Cosφ= 0.3
Sinφ= 0.95
(h) 240 V AC feeders:

Cable sizes are computed on the basis of different feeder ratings.
(i) 220 V DC feeders:

Cable sizes are computed on the basis of different feeder ratings.
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(j) Voltage drop limits considered are as under:
i) 415 V AC Supply Feeders

- Steady State (continuous running condition) 2.5 %
ii) 415 V AC Motor Feeders
- Steady State (continuous running condition) 2.5 %
- Transient State (during motor starting condition) 10 %
iii) 240 V AC Supply Feeders 10 V
iv) 220 V DC Feeders

- Battery to DCDB 1.66 V
- Charger to DCDB 1.66 V
- DCDB to loads/Motors 4V
4.2 DESIGN CONSIDERATIONS: CONTROL CABLES
4.2.1 No sizing calculations are required for control cables. The following considerations are applicable to the
selection of these cables:
a) Control cables are of 1.5 mm.& 2.5 mm. cross-section, and with up to 24 cores.
4.2.2 Minimum no. of spare cores in control cables shall be as follows:

No. of cores in cable No. of spare cores (minimum)
2C, 3C, 4C NIL
5C 1
7C-10C 2
14C and above 3
4.3 DESIGN INPUT DATA
The following data is used as the basis input data for sizing & selection of cables.
(a) Design ambient temperature: 50 °C
(b) Fault current for 11 kV & 3.3 kV systems: 40 kA RMS

(As per NTPC TS E0, Part-B, Cl.1.08)
(c) Fault current for 415V systems: 50 kA RMS

(As per NTPC TS E0, Part-B, Cl.1.08)
(d) Main protection fault clearing time for cables 0.12 sec. (min)
to the feeders protected by breakers:
(As per NTPC TS E0, Part-B, Cl. 6.0 (vi))
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(e) Annexure-B: Cable Technical Data

- Current ratings (AC/DC)-CABLE CATALOGUE OF UNIVERSAL CABLES LIMITED
Table-21 Current ratings for two single core 650/1100 V unarmoured or non-magnetic armoured PVC
cables according to IS-1554 (I).
Table-23 Current ratings for twin 650/1100 V armoured or unarmoured PVC cables according to IS-1554
(I).
Table-24 Current ratings for three, three and half and four core 650/1100V armoured or unarmoured
PVC cables according to IS-1554 (I).
Table-29 Current ratings for two single core 650/1100 V unarmoured or non magnetic armoured 1.1 kV
XLPE cables according to IS-7098 (I).
Table-30 Current ratings for three single core 650/1100 V unarmoured or non-magnetic armoured 1.1 kV
XLPE cables according to IS-7098 (1).
Table-31 Current ratings for twin 650/1100 V armoured or unarmoured 1.1 kV XLPE cables to IS-7098
(I).
Table-32 Current ratings for three, three and half and four core 650/1100V armoured or unarmoured 1.1
kV XLPE cables according to IS-7098 (I).
Table-33 Current ratings for three single core 1.9/3.3 kV & 3.3/3.3 kV XLPE cables according to IS-7098
(II).
Table-36 Current ratings for three single core 11/ 11 kV XLPE cables according to IS-7098 (II).
Table-39 Current ratings for three core 1.9/ 3.3 kV & 3.3 /3.3 kV XLPE cables according to IS-7098 (II).
Table-42 Current ratings for three core 11/11 kV XLPE cables according to IS-7098 (II).
- Resistances & Reactances-CABLE CATALOGUE OF UNIVERSAL CABLES LIMITED
Table-62 Approximate AC resistance of conductor (Ohm/ km) at maximum operating conductor

temperature PVC, HR PVC and XLPE cables.
Table-63 Approximate reactance at 50 Hz (Ohms/km), 1.1 kV PVC, HR PVC and XLPE cables.
- Derating factors for installation conditions-CABLE CATALOGUE OF UNIVERSAL CABLES LIMITED
Table-49 Rating factors for variation in ground temperature for cables laid direct in ground.
Table-51 Rating factors for variation in ambient air temperature.
Table-52 Rating factors for variation in thermal resistivity of soil for three single core cables laid direct in
ground in trefoil touching.
Table-54 Rating factors for variation in thermal resistivity of soil for twin and multi-core cables laid direct
in ground.
Table-56 Rating factors for variation in depth of laying for cables laid directly in ground.
Table-58 Group rating factors for single core cables laid in trefoil formation.
Table-59 Group rating factors for multi core cables.
UCL Table Group rating factor for multi-core cables under the conditions given in Table 59 (A) but the
cables are touching.
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4.3.1 DESIGN INPUTS FOR CABLE SIZING FOR 11 kV & 3.3 kV SYSTEM
(a) MINIMUM SIZE FOR SHORT CIRCUIT CURRENT WITHSTAND CAPACITY
All 11 kV and 3.3 kV feeders are circuit breaker protected.

Fault current Ish = 40 kA RMS
Fault clearing time t = 0.12 sec. ( min.)
Minimum cross-sectional area to withstand short circuit A= Ish x SQRT(t) / k
where k is a constant (for aluminium conductor XLPE insulation) = 0.094
(R f A
Therefore, A= 147.41 mm2
Nearest standard cable conductor size selected= 150 mm2
(b) CABLE SIZES BASED ON LOAD CURRENT CARRYING CAPACITY : DERATING FACTORS
Cables are rated for laying in the following conditions:

(i) Cables in air
Free air circulation conditions (cables laid in cable trays in cable vaults/ overhead pipe-cum-cable trestle) for all
cables in Main power house area. Derating factors for cables laid in air are listed below:
(1) Temperature derating factor (K1)
For 50 deg. C ambient temperature, derating factor (K1)= 0.9
( refer Table-51 )
(2) Group derating factor (K2)
No. of cores Arrangement of cables K2 Table ref.

Single core 3 Trays & 3 no. of trefoils per tray, separated by 2 cable dia 0.92 Table 58 (D)
Multi core 3 Trays & 6 cables/tray, cables touching 0.70 Table 59 (C)
Overall derating factor = K1 x K2

For single core HT cables (Khas)= = 0.83
For multi core HT cables (Kham)= = 0.63
(ii) Cables laid directly in ground

Such cables as may be required to be buried directly in ground to meet statutory requirements (e.g. for fire
fighting system equipment etc.). Derating factors for cables laid directly in ground are listed below:
(1) Temperature derating factor (K3)
For 40 deg. C ground temperature, derating factor = 0.91
( refer Table-49 )
(2) Group derating factor (K4)=

Single core 1 no. of trefoil (touching) 1 (*)
Multi core 1 no. cable in horizontal formation 1 (*)
(*): No group derating is considered as single cable is buried in ground
(3) Derating factor for variation in thermal resistivity of soil (150 deg. C cm/ W) (K5)= 1
(Refer Table-52 & 54)
(4) Derating factor for depth of laying (K6)= 1
(depth of laying considered=0.9m.)
(Refer Table-56)
Overall derating factor
= K3 x K4 x K5 x K6
For single core HT cables (KHgs) = 0.91
For multi core HT cables (KHgm) = 0.91
(c) CABLE SIZES BASED ON VOLTAGE DROP CRITERIA
Voltage drop for 11 kV & 3.3 kV cables is found to be insignificant compared to allowable limits, with the sizes
chosen on the basis of fault current withstand capacity and load current carrying criteria.
4.3.2 DESIGN INPUTS FOR CABLE SIZING FOR 415 V SYSTEM
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(a-1) MINIMUM SIZE FOR SHORT CIRCUIT CURRENT WITHSTAND CAPACITY-CIRCUIT BREAKER
PROTECTED FEEDERS
Outgoing feeders from 415V boards (Circuit breaker protected)
Fault current Ish = 50 kA RMS

Fault clearing time t = 0.12 sec. ( min.)
Minimum cross-sectional area to withstand Short circuit current (A)= Ish.SQRT(t)/k
where k is a constant (for Al. conductor XLPE insulation) 0.094
Therefore, A (Al. conductor XLPE insulation)= 184.26 mm2

Nearest standard cable conductor size for aluminium conductor XLPE 185 mm2
insulation=
However to meet voltage drop criteria, cable conductor size selected 300 mm2
for aluminium conductor XLPE insulation=
(a-2) CABLE SIZES BASED ON SHORT CIRCUIT CURRENT WITHSTAND CAPACITY- FUSE PROTECTED
FEEDERS
For fuse protected feeders, minimum cable size of 2.5 sq. mm. (copper) or 6 sq. mm. (aluminium) is taken in line
with Cl. 5.01 , Part-B, Section-VI, Sub-section-E18 of NTPC Technical Specification.
Cables are rated for laying in the following conditions:
(i) Cables in air

Free air circulation conditions (cables laid in cable trays in cable vaults/ overhead pipe-cum-cable trestle) for all
cables in Main power house area except for cables mentioned at (iii). Derating factors for cables laid in air are
listed below:
(1) Temperature derating factor (refer Table-51)
For 50 deg. C ambient temperature, derating factor (K1) for XLPE cables= 0.9
For 50 deg. C ambient temperature, derating factor (K7) for PVC cables= 0.81
(2) Group derating factor(K8)
Single core 3 Trays & 3 no. of trefoils per tray, separated by 2 cable dia 0.92 Table 58 (D)
Multi core 6 Trays & 6 no. of cables per tray in air, touching each other 0.68 Table 59 (C)
Overall derating factor K

= K1 x K8 (XLPE)
= K7 x K8 (PVC)
For XLPE, single core LT cables (KLasx) = 0.83
For PVC, single core LT cables (KLasp) = 0.75
For XLPE, multi core LT cables (KLamx) = 0.61
For PVC, multi core LT cables (KLamp) = 0.55
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(ii) Cables laid directly in ground
Such cables as may be required to be buried directly in ground to meet statutory requirements (e.g. for fire
fighting system equipment etc.). Derating factors for cables laid in ground are listed below:
(1) Temperature derating factor (refer Table-45)
For 40 deg. C ground temperature, derating factor,K3 (XLPE cables) = 0.91

( refer Table-49 )
For 40 deg. C ground temperature, derating factor,K9 (PVC cables)= 0.87
( refer Table-49 )
(2) Group derating factor (K4)=

Single core 3 no. of trefoils in horizontal formation (touching) 0.68 Table 58 (A)
Multi core 3 no. cables in horizontal formation (touching) 0.69 Table 59 (D)
(3) Derating factor for variation in thermal resistivity of soil (150 deg. C/cm/W) (K11)= 1
(refer Tables-52 & 54)
(4) Derating factor for depth of laying (K12)= 1
(depth of laying considered=0.75m.)
(refer Table-56)
Overall derating factor K
= K3 x K4 x K11 x K12
= K9 x K4 x K11 x K12
For single core XLPE, LT cables (KLgsx) = 0.62
For single core PVC, LT cables KLgsp = 0.59
For multi core XLPE, LT cables (KLgmx) = 0.63
For multi core, PVC LT cables (KLgmp) = 0.60
(iii) Cables in covered trench with restricted air circulation.

Restricted air circulation conditions (cables laid in cable trays in cable trenches e.g. in auxiliary plant areas).
Derating factors for cables in covered trench with restricted air circulation are listed below:
(1) For 50 deg. C ambient temperature, derating factor (K1) for XLPE cables= 0.9
( refer Table-51 )
For 50 deg. C ambient temperature, derating factor (K7) for PVC cables= 0.81
( refer Table-51 )
(2) Group derating factor (K14)

Single core 3 Trays & 3 no. of trefoils per tray, separated by 2 cable dia 0.81 Table 58 (C)
Multi core 3 Trays & 9 cables/tray, cables touching 0.60 UCL Table
Overall derating factor = K1 x K13

For single core XLPE, LT cables (KLtsx) = 0.73
For single core PVC, LT cables KLtsp = 0.66
For multi core XLPE, LT cables (KLtmx) = 0.54
For multi core, PVC LT cables (KLtmp) = 0.49
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(c) CABLE SIZES BASED ON VOLTAGE DROP CRITERIA (415 V SYSTEM)
Cable size based on voltage drop limits:
The voltage drop for a given cable length under steady state conditions is given by the formula
Voltage drop in %= 3 * I * l * (R * tcor * Cosφ + X * Sinφ )

* 100
V
Where:
I= Full Load current in Amperes for steady state conditions
Starting current for transient conditions (for motor feeders)
l= Feeder length in metres
R= AC Resistance of cable in Ohm/km
X= Reactance of cable in Ohm/km at 50 Hz.
Under starting conditions for LT motors, the voltage drop is also checked with 7.2 times the full load current as
starting current and power factor taken as 0.3.
4.3.3 DESIGN INPUTS FOR CABLE SIZING FOR 220 V DC SYSTEM
(a) MINIMUM SIZE FOR SHORT CIRCUIT CURRENT WITHSTAND CAPACITY-FUSE PROTECTED FEEDERS
For fuse protected feeders, minimum cable size of 2.5 sq. mm. (copper) or 6 sq. mm. (aluminium) is taken in line
with Cl. 5.01 , Part-B, Section-VI, Sub-section-E18 of NTPC Technical Specification.
Derating factors for 220 V DC system are taken same as for 415 V system listed at 4.3.2 (b) above.
(c) CABLE SIZES BASED ON VOLTAGE DROP CRITERIA
The voltage drop for a given cable length is given by the formula
Voltage drop= 2 * I * l * R * t cor

1000
Where:
I= Full Load current in Amperes for steady state conditions
l= Feeder length in metres
R= Resistance of cable in Ohm/km
5.0 SAMPLE CALCULATIONS

5.1 11 kV FEEDERS
5.1.1 FEEDER FROM 11 kV BOARD 9BA TO UNIT AUXILIARY TRANSFORMER # 9CAT01
(a) Fault Current Criterion
Minimum size = 150 sq. mm.

(CB protected feeder)
(b) Load Current Criterion
Rating Of the Transformer # 9CAT01= 16000 kVA

Full load Current=16000 /(SQRT(3) * 11)= 839.78 A
Overall Derating Factor for 3-core HT cables laid in air (KHas)= 0.83
Uprated load current=839.78/0.83= 1011.78 A
From Annex.-B, Table-36, current rating of 1C-300 sq. mm. Cable in air= 518 A
Hence Cable size for load current=2-1C-300 sq. mm.
Final cable size selected is 2-1C-500 sq mm.
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5.1.2 FEEDER FROM 11 kV BOARD 0BA TO MDBFP

Rating Of MDBFP= 10000 kW

Full load Current=10000 /(SQRT(3) * 11*0.9*0.9)= 647.98 A
Overall Derating Factor for 1-core HT cables laid in air KHas= 0.83
From Annex.-B, Table-36, current rating of 1C-630 sq. mm. cable in air= 822 A
Hence Cable size for load current= 1C-630 sq. mm./ph.
Final cable size selected is 2-1C-500 sq mm. /ph
Cable sizing for 11 kV feeders is shown in Table-A of Annexure-'A'.
5.2 3.3 kV FEEDERS
5.2.1 FEEDER FROM 3.3 kV BOARD 9CA TO FD FAN-9A

Rating Of FD Fan = 1300 kW

Full load Current=1300/(SQRT(3) * 3.3*0.85*0.9)= 297.31 A
Overall Derating Factor for 1-core HT cables laid in air KHas= 0.83
From Annex.-B, Table-33, current rating of 1C-185 sq. mm. Cable in air= 362 A
Hence Cable size for load current= 1C-185 sq. mm.
Final cable size selected is 1C-300 sq mm./ph.
Cable sizing for 3.3 kV feeders is shown in Table-B-1 of Annexure-'A'.

Cable sizing for 3.3 kV feeders for VFD system is shown in Table-B-2 of Annexure-'A'.
5.3 415 V SUPPLY FEEDERS ( LAID IN AIR)

5.3.1 Supply Feeder of standard rating 630 Amp.
Corresponding to rating (0.9*630)= 567 A

Overall Derating Factor for XLPE-1-core LT cables laid in air (KLasx)= 0.83
Uprated load current=567/0.83 683.13 A
From Annex.-B,Table-24, current rating of 1C-630 sq. mm. (Al) Cable in air= 814 A
Hence Cable size for load current= 1C-630 sq. mm./ph
The neutral cable is sized on the basis of half the uprated load current. Cable size selected for neutral cable is
1C-400 sq. mm. (Al) sq. mm.
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(c) Voltage Drop Criterion
(i) Steady State Conditions

The voltage drop for a given cable length under steady state conditions is given by the formula:
3 * I * l * (R * tcor * Cosφ + X * Sinφ )
* 100
V
where:
Load current (I) in A.= 567 A
Resistance (R) of 630 mm2 conductor at 90 deg. C = 0.065 Ohms/km.
(Refer Table-62)
Reactance (X) of 630 mm2 at 90 deg. C with XLPE insulation= 0.0765 Ohms/km.
(Refer Table-63)
Cosφ= 0.85
Sinφ= 0.53
Feeder length= 50 m.
Voltage drop in % for 1C-630 sq. mm. = 1.13 %
Since this voltage drop is less than the permissible limit of 2.5%, cable size of 1C-630 sq. mm./ph is adequate.
For feeder lengths of 100m, 150m and 200 m, cable sizes selected are 1C-630 sq. mm. (Al)/ph, 2-1C-400 sq.
mm. (Al)/ph & 2-1C-630 sq. mm. (Al)/ph respectively and the corresponding voltage drops are 2.27 %, 2.28 %
and 2.27 % respectively, which are less than the permissible limit of 2.5 %.
Cable sizing for 415 V supply feeders (in air) is shown in Table-C of Annexure-'A'.
5.4 415 V SUPPLY FEEDERS ( LAID IN TRENCH)

Cable sizing for 415 V supply feeders (in trench) is shown in Table-D of Annexure-'A'.
5.5 415 V MOTOR FEEDERS, IN AIR
5.5.1 Motors rated from 0.01 kW to 1 kW
Minimum size = 2.5 sq. mm.
Corresponding to rating = 1 kW
Full load Current=1.0*1000 /(SQRT(3) * 415*0.7*0.74)= 2.69 A
Overall Derating Factor for PVC 3-core LT cables laid in air (KLamp)= 0.55
From Annex.-B, Table-24, current rating of 3C-2.5 sq. mm. (Cu) Cable in air= 24 A
Hence Cable size for load current of 4.88 A= 3C-2.5 sq. mm.
For motor feeders, the voltage drop is calculated for both steady state (running) conditions, as well as transient
state (starting) conditions. The voltage drop is calculated for feeder lengths of 50m, 100m, 150m and 200m. The
actual cable size for any load can be chosen after determining it's cabling distance from the feeding
switchboard.
13 of 16
Doc. No.
PE-DC-209-507-E003
Rev No. 0
January 21, 2004
(i) Steady State Conditions

where: *100
V
Load current (I) in A.= 2.69 A
Resistance (R) of 2.5 mm2 Cu conductor at 70 deg. C = 8.89 Ohms/km.
(Refer Table-62)
Reactance (X) of 2.5 mm2 at 70 deg. C with PVC insulation= 0.106 Ohms/km.
(Refer Table-63)
Cosφ= 0.7
Sinφ= 0.71
Voltage drop in % for 3C-2.5 sq. mm. = 0.35 %
Since this voltage drop is less than the permissible limit of 2.5%, selected cable size is 1 no. 3C-
2.5 sq. mm.
From the above calculations, it is clear that for feeder lengths of 100m, 150m and 200m, steady state voltage
drop for 1-3C-2.5 sq. mm. size for load current of 2.69 A. is 0.71 %, 1.06 % and 1.41 % respectively, which is
less than the permissible limit of 2.5 %.
Hence, cable size of 1 no. 3C-2.5 sq. mm. is adequate.
(ii) Transient State Conditions

The voltage drop for a given cable length under transient state conditions is given by the formula:
3 * I st * l * (R * tcor * Cosφt + X * Sin φt )
V
where:
Starting current (Ist) in A.=7.2*I 19.34 A
Resistance (R) of 2.5 mm2 Cu conductor at 70 deg. C = 8.89 Ohms/km.
(Refer Table-62)
Reactance (X) of 2.5 mm2 at 70 deg. C with PVC insulation= 0.106 Ohms/km.
(Refer Table-63)
Cosφ= 0.3
Sinφ= 0.95
Voltage drop in % for 3C-2.5 sq. mm. for starting current of 19.37 A.= 1.12 %
Since this voltage drop is less than the permissible limit of 10 %, cable size of 1 no. 3C-2.5 sq. mm. is adequate.
From the above calculations, it is clear that for feeder lengths of 100m, 150m and 200m, steady state voltage
drop for 1-3C-2.5 sq. mm. size for starting current of 19.37 A. is 2.23 %, 3.35 % and 4.47 % respectively, which
is less than the permissible limit of 10 %.
Hence, cable size of 1 no. 3C-2.5 sq. mm. is adequate.
14 of 16
Doc. No.
PE-DC-209-507-E003
Rev No. 0
January 21, 2004
5.5.2 Motors rated from 18.51 kW to 22 kW


Corresponding to rating = 22 kW
Full load Current=22*1000 /(SQRT(3) * 415*0.84*0.84)= 43.38 A
Overall Derating Factor for PVC 3-core LT cables laid in air (KLamp)= 0.55
From Annex.-B, Table-24, current rating of 3C-50 sq. mm. (Al) Cable in air= 105 A
Hence Cable size for load current= 3C-50 sq. mm.

(I) Steady State Conditions

* 100
V
where:
Load current (I) in A.= 43.38 A
(Refer Table-62)
Reactance (X) of 50 mm2 at 70 deg. C with PVC insulation= 0.0765 Ohms/km.
(Refer Table-63)
Cosφ= 0.84
Sinφ= 0.54
Voltage drop in % for 3C-50 sq. mm. for load current of 43.38A.= 0.62 %
Since this voltage drop is less than the permissible limit of 2.5%, cable size of 1 no. 3C-50 sq. mm. is adequate.
From the above calculations, it is clear that for feeder lengths of 100m, 150m & 200 m, steady state voltage drop
for 1-3C-50 sq. mm. size for load current of 43.38 A. is 1.25%, 1.87 and 2.49 % respectively, which is less than
the permissible limit of 2.5 %.
Hence, cable size of 1 no. 3C-50 sq. mm. is adequate.
(ii) Transient State Conditions

The voltage drop for a given cable length under transient state conditions is given by the formula:
3 * I st * l * (R * tcor * Cosφt + X * Sin φt )
V
where:
Starting current (Ist) in A.=7.2*I 312.31 A
(Refer Table-62)
Reactance (X) of 50 mm2 at 70 deg. C with PVC insulation= 0.0765 Ohms/km.
(Refer Table-63)
Cosφ= 0.3
Sinφ= 0.95
Voltage drop in % for 3C-50 sq. mm. for starting current of 312.31 A.= 1.98 %
Since this voltage drop is less than the permissible limit of 10 %, cable size of one no. 3C-50 sq. mm. is
adequate.
From the above calculations, it is clear that for feeder lengths of 100m, 150m and 200 m, transient state voltage
drop for 1-3C-50 sq. mm. size for starting current of 312.34 A. is 3.96, 5.94% and 7.92 % respectively, which is
less than the permissible limit of 10 %.
Hence, cable size of 1-3C-50 sq. mm. is adequate.
Cable sizing for 415 V motor feeders ( in air) is shown in Table-E of Annexure-'A'.
15 of 16
Doc. No.
PE-DC-209-507-E003
Rev No. 0
January 21, 2004
5.6 415 V MOTOR FEEDERS, IN TRENCH

Cable sizing for 415 V motor feeders ( in trench) is shown in Table-F of Annexure-'A'.
5.7 240 V AC SUPPLY FEEDERS, LAID IN AIR

Cable sizing for 240 V AC supply feeders (laid in air) is shown in Table-G of Annexure'A'.
5.8 240 V AC SUPPLY FEEDERS, LAID IN TRENCH

Cable sizing for 240 V AC supply feeders (laid in trench) is shown in Table-H of Annexure'A'.
5.9 220 V DC SUPPLY FEEDERS (IN AIR)
5.9.1 Supply Feeder for 400 A rating
Corresponding to actual loading= 400 A

Overall Derating Factor for XLPE single-core LT cables laid in air (KLasx)= 0.83
Uprated load current=400/0.83 481.93 A
(From Table-29), current rating of 1C-400 mm2 cable= 669
cable size as per load current criteria= 1C-400 sq. mm.
(I) Steady State Conditions

The voltage drop for a given cable length ( in volts) under steady state conditions is given by the
2 * I * l * R * t cor
where: 1000
Load current (I) in A.= 400 A
Resistance (R) of 630 sq. mm conductor at 90 deg. C = 0.065 Ohms/km.
(Refer Table-62)
Voltage drop in volts for 1C-630 sq. mm. for load current of 20 A.= 1.30 V
Since this voltage drop is less than the permissible limit of 1.66 volts, cable size of 1C-630 sq. mm. is adequate
for feeder length of 25 m.
Cable sizing for 220 V DC supply feeders (in air) for different feeder lengths is shown in Table-I of
Annexure'A'.
6.0 Cable sizes finalised for the project are indicated at Annexure-C.
16 of 16
ANNEXURE- ‘A’:
SELECTION TABLE FOR CABLE SIZES
TABLE-A: CABLE SELECTION TABLE FOR 11 kV SYSTEM
(CABLES LAID IN AIR EXCEPT FOR THOSE LISTED OUT IN 'REMARK' COLUMN)
2 X 500 MW VINDHYACHAL STPP, STAGE-III
DOC. NO:PE-DC-209-507-E003, R-0 January 21, 2004
NAME PLATE kW
A=Ish x sqrt. (t)/k
BASE CURRENT
(Amps.) =FLC/K
CABLE SIZE
FULL LOAD
K FACTOR
CURRENT
Efficiency
CABLE SIZE AS
RATING
(in kVA)
(Amps.)
BASED ON
SL. PER LOAD SELECTED CABLE SIZE
p.f.
FEEDER DESCRIPTION S/C REMARK
NO. CURRENT sq. mm.
CURRENT
sq. mm.
sq. mm.
A OUT GOING FEEDER FROM 11KV BOARD 9BA
1 TRANSFORMER FEEDER TO UAT#9CAT01 16000 839.78 147.41 150 0.83 1011.79 2-1C-300/ph 2-1C-500/ph
2 TRANSFORMER FEEDER TO 9DAT01 2000 104.97 147.41 150 0.63 166.62 3C-70 3C-150
UNIT-9 SERVICE TRANSFORMER
3 TRANSFORMER FEEDER TO 9DBT01 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
UNIT-9 EP SERVICE TRANSFORMER
4 TRANSFORMER FEEDER TO 9DCT01 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
5 TRANSFORMER FEEDER TO 9DDT01 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
6 TRANSFORMER FEEDER TO 9DET01 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
7 TRANSFORMER FEEDER TO COOLING TOWER 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
TRANSFORMER # 9A
8 TRANSFORMER FEEDER TO ASH HANDLING SERVICE 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
TRANSFORMER # 9A
9 CWP#1 (NTPC) 2800 0.75 0.90 4148 217.72 147.41 150 0.83 262.31 1C-120/ph 1C-150/ph
10 PA FAN-9A 2950 0.90 0.90 3642 191.15 147.41 150 0.83 230.31 1C-95/ph 1C-150/ph
11 VFD ID FAN-9A (CH#1) 4050 0.90 0.90 5000 262.43 147.41 150 0.83 316.18 1C-150/ph 1C-150/ph
12 VFD ID FAN-9A (CH#2) 4050 0.90 0.90 5000 262.43 147.41 150 0.83 316.18 1C-150/ph 1C-150/ph
B OUT GOING FEEDER FROM 11KV BOARD 9BB
1 TRANSFORMER FEEDER TO UAT#9CAT01 16000 839.78 147.41 150 0.83 1011.79 2-1C-300/ph 2-1C-500/ph
2 TRANSFORMER FEEDER TO 9DAT02 2000 104.97 147.41 150 0.63 166.62 3C-70 3C-150
UNIT-9 SERVICE TRANSFORMER
3 TRANSFORMER FEEDER TO 9DBT02 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
4 TRANSFORMER FEEDER TO 9DCT02 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
5 TRANSFORMER FEEDER TO 9DDT02 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
6 TRANSFORMER FEEDER TO 9DET02 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
1 of 7
NAME PLATE kW
A=Ish x sqrt. (t)/k
BASE CURRENT
(Amps.) =FLC/K
CABLE SIZE
FULL LOAD
K FACTOR
CURRENT
Efficiency
CABLE SIZE AS
RATING
(in kVA)
(Amps.)
BASED ON
p.f.
NO. CURRENT sq. mm.
CURRENT
sq. mm.
sq. mm.
TRANSFORMER # 9B
TRANSFORMER # 9C
9 TRANSFORMER FEEDER TO ASH HANDLING SERVICE 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
TRANSFORMER # 9B
10 CWP#2 (NTPC) 2800 0.75 0.90 4148 217.72 147.41 150 0.83 262.31 1C-120/ph 1C-150/ph
11 PA FAN-9B 2950 0.90 0.90 3642 191.15 147.41 150 0.83 230.31 1C-95/ph 1C-150/ph
12 VFD ID FAN-9B (CH#1) 4050 0.90 0.90 5000 262.43 147.41 150 0.83 316.18 1C-150/ph 1C-150/ph
13 VFD ID FAN-9B (CH#2) 4050 0.90 0.90 5000 262.43 147.41 150 0.83 316.18 1C-150/ph 1C-150/ph
C OUT GOING FEEDER FROM 11KV BOARD 0BA
1 UNIT-9 MDBFP 10000 0.9 0.9 12346 647.98 147.41 150 0.83 780.70 1C-630/ph 2-1C-500/ph
2 TRANSFORMER FEEDER TO SWITCHYARD SERVICE 1000 52.49 147.41 150 0.63 83.31 3C-25 3C-150
TRANSFORMER-1
3 TRANSFORMER FEEDER TO BUNKER SERVICE 1250 65.61 147.41 150 0.63 104.14 3C-25 3C-150
TRANSFORMER-1
4 TRANSFORMER FEEDER TO 11/ 34.5 kV AWRS 3000 157.46 147.41 150 0.63 249.94 3C-120 3C-150
TRANSFORMER-1
5 TRANSFORMER FEEDER TO ASH WATER TRANSFORMER-1 2000 104.97 147.41 150 0.63 166.62 3C-70 3C-150
6 TRANSFORMER FEEDER TO ETP SERVICE TRANSFORMER-1 630 33.07 147.41 150 0.63 52.49 3C-25 3C-150
7 TRANSFORMER FEEDER TO CHP TRANSFORMER-1 2000 104.97 147.41 150 0.63 166.62 3C-70 3C-150
8 TRANSFORMER FEEDER TO COAL HANDLING PLANT 6300 330.66 147.41 150 0.83 398.39 1C-240/ph 1C-500/ph
TRANSFORMER
9 TRANSFORMER FEEDER TO WTP SERVICE TRANSFORMER 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
10 TRANSFORMER FEEDER TO OFFSITE SERVICES SERVICE 2000 104.97 147.41 150 0.63 166.62 3C-70 3C-150
TRANSFORMER # 0DDT01
11 TRANSFORMER FEEDER TO STATION SERVICE 2000 104.97 147.41 150 0.63 166.62 3C-70 3C-150
TRANSFORMER (UNIT-9) # 0DAT01
12 TRANSFORMER FEEDER TO FUEL OIL AREA SERVICE 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
TRANSFORMER
2 of 7
NAME PLATE kW
A=Ish x sqrt. (t)/k
BASE CURRENT
(Amps.) =FLC/K
CABLE SIZE
FULL LOAD
K FACTOR
CURRENT
Efficiency
CABLE SIZE AS
RATING
(in kVA)
(Amps.)
BASED ON
p.f.
NO. CURRENT sq. mm.
CURRENT
sq. mm.
sq. mm.
D OUT GOING FEEDER FROM 11KV BOARD 0BB
TRANSFORMER (UNIT-10) # 0DBT01
2 TRANSFORMER FEEDER TO FIRE WATER P/H 2000 104.97 147.41 150 0.91 115.35 3C-50 3C-150 (A) CABLES BURIED
TRANSFORMER # 0DCT01 DIRECTLY IN GROUND
3 TRANSFORMER FEEDER TO CW SERVICE TRANSFORMER #1 1000 52.49 147.41 150 0.63 83.31 3C-25 3C-150
4 CWP# 5 (NTPC) 2800 0.9 0.75 4148 217.72 147.41 150 0.83 262.31 1C-120/ph 1C-150/ph
5 MAKE-UP/ RAW WATER PLANT TRANSFORMER #1 2000 104.97 147.41 150 0.63 166.62 3C-70 3C-150
6 ASH HANDLING PLANT 8000 419.89 147.41 150 0.83 505.89 1C-300/ph 1C-500/ph
7 SILO SERVICE TRANSFORMER #1 1250 65.61 147.41 150 0.63 104.14 3C-25 3C-150
9 TRANSFORMER FEEDER TO RAW WATER P/H AREA SERVICE 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
TRANSFORMER
E OUT GOING FEEDER FROM 11KV BOARD 0BD
TRANSFORMER (UNIT-10) # 0DBT02
2 TRANSFORMER FEEDER TO FIRE WATER P/H 2000 104.97 147.41 150 0.91 115.35 3C-50 3C-150 (A) CABLES BURIED
TRANSFORMER # 0DCT02 DIRECTLY IN GROUND
3 TRANSFORMER FEEDER TO CW SERVICE TRANSFORMER 1000 52.49 147.41 150 0.63 83.31 3C-25 3C-150
(UNIT-9) # 0DCT03
4 MAKE-UP/ RAW WATER PLANT 2000 104.97 147.41 150 0.63 166.62 3C-70 3C-150
5 ASH HANDLING PLANT 8000 419.89 147.41 150 0.83 505.89 1C-300/ph 1C-500/ph
6 SILO SERVICE TRANSFORMER 1250 65.61 147.41 150 0.63 104.14 3C-25 3C-150
8 TRANSFORMER FEEDER TO RAW WATER P/H AREA SERVICE 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
TRANSFORMER
3 of 7
NAME PLATE kW
A=Ish x sqrt. (t)/k
BASE CURRENT
(Amps.) =FLC/K
CABLE SIZE
FULL LOAD
K FACTOR
CURRENT
Efficiency
CABLE SIZE AS
RATING
(in kVA)
(Amps.)
BASED ON
p.f.
NO. CURRENT sq. mm.
CURRENT
sq. mm.
sq. mm.
F OUT GOING FEEDER FROM 11KV BOARD 0BC
1 UNIT-10 MDBFP 10000 0.9 0.9 12346 647.98 147.41 150 0.83 780.70 1C-630/ph 2-1C-500/ph
2 TRANSFORMER FEEDER TO SWITCHYARD SERVICE 1000 52.49 147.41 150 0.63 83.31 3C-25 3C-150
TRANSFORMER-2
3 TRANSFORMER FEEDER TO BUNKER SERVICE 1250 65.61 147.41 150 0.63 104.14 3C-25 3C-150
TRANSFORMER-2
4 TRANSFORMER FEEDER TO 11/ 34.5 kV AWRS 3000 157.46 147.41 150 0.63 249.94 3C-120 3C-150
TRANSFORMER-1
5 TRANSFORMER FEEDER TO ASH WATER TRANSFORMER-2 2000 104.97 147.41 150 0.63 166.62 3C-70 3C-150
6 TRANSFORMER FEEDER TO ETP SERVICE TRANSFORMER-2 630 33.07 147.41 150 0.63 52.49 3C-25 3C-150
8 TRANSFORMER FEEDER TO COAL HANDLING PLANT 6300 330.66 147.41 150 0.83 398.39 1C-240/ph 1C-500/ph
TRANSFORMER
9 TRANSFORMER FEEDER TO WTP SERVICE TRANSFORMER 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
10 TRANSFORMER FEEDER TO OFFSITE SERVICES SERVICE 2000 104.97 147.41 150 0.63 166.62 3C-70 3C-150
TRANSFORMER # 0DDT02
TRANSFORMER (UNIT-9) # 0DAT02
12 TRANSFORMER FEEDER TO FUEL OIL AREA SERVICE 1600 83.98 147.41 150 0.63 133.30 3C-50 3C-150
TRANSFORMER
NOTES:
1 Equipment & their ratings are indicated on the basis of Electrical Single Line Diagram for Auxiliary Power Distribution (drawing no. PE-DG-209-565-E001). In case of any change in rating of any of the equipment listed above, or
addition of any loads, this table will be suitably amended.
2 In case of change of installation conditions of any feeder cable, the cable size/ type shall be checked for the new installation conditions and changed if required.
4 of 7
TABLE-B1: CABLE SELECTION TABLE FOR 3.3 kV SYSTEM
DOC. NO: PE-DC-209-507-E003, R-0 January 21, 2004
CABLE SIZE
FULL LOAD
K FACTOR
PLATE kW
CURRENT
CURRENT
Efficiency
CABLE SIZE AS
sqrt. (t)/k
RATING
(in kVA)
(Amps.)
(Amps.)
A=Ish x
=FLC/k
BASED ON SELECTED
NAME
BASE
SL. PER BASE
FEEDER DESCRIPTION p.f. S/C CABLE SIZE REMARK
NO. CURRENT
CURRENT sq. mm.
sq. mm.
sq. mm.
A OUT GOING FEEDER FROM 3.3 kV BOARD 9CA
1 CEP-9A 0.85 0.9 900 1176 205.83 147.41 150 0.83 247.99 1C-120/ph 1C-150/ph
2 CEP-9B 0.85 0.9 900 1176 205.83 147.41 150 0.83 247.99 1C-120/ph 1C-150/ph
3 CEP-9C 0.85 0.9 900 1176 205.83 147.41 150 0.83 247.99 1C-120/ph 1C-150/ph
4 FD FAN-9A 0.85 0.9 1300 1699 297.31 147.41 150 0.83 358.20 1C-185/ph 1C-300/ph
5 FD FAN-9B 0.85 0.9 1300 1699 297.31 147.41 150 0.83 358.20 1C-185/ph 1C-300/ph
6 ECW PUMP(TG)-9A 0.85 0.9 270 353 61.75 147.41 150 0.63 98.01 3C-35 3C-150
7 ECW PUMP (TG)-9B 0.85 0.9 270 353 61.75 147.41 150 0.63 98.01 3C-35 3C-150
8 ECW PUMP (TG)-9C 0.85 0.9 270 353 61.75 147.41 150 0.63 98.01 3C-35 3C-150
9 ECW PUMP (SG)-9A 0.85 0.9 380 497 86.91 147.41 150 0.63 137.95 3C-50 3C-150
10 ECW PUMP (SG)-9B 0.85 0.9 380 497 86.91 147.41 150 0.63 137.95 3C-50 3C-150
11 BCWP-9A 0.85 0.9 350 458 80.04 147.41 150 0.83 96.44 1C-25 1C-150/ph
12 BCWP-9B 0.85 0.9 350 458 80.04 147.41 150 0.83 96.44 1C-25 1C-150/ph
13 BCWP-9C 0.85 0.9 350 458 80.04 147.41 150 0.83 96.44 1C-25 1C-150/ph
14 MILL-A 0.7 0.9 525 833 145.80 147.41 150 0.63 231.42 3C-120 3C-150
15 MILL-B 0.7 0.9 525 833 145.80 147.41 150 0.63 231.42 3C-120 3C-150
16 MILL-C 0.7 0.9 525 833 145.80 147.41 150 0.63 231.42 3C-120 3C-150
17 MILL-D 0.7 0.9 525 833 145.80 147.41 150 0.63 231.42 3C-120 3C-150
18 MILL-E 0.7 0.9 525 833 145.80 147.41 150 0.63 231.42 3C-120 3C-150
5 of 7
TABLE-B1: CABLE SELECTION TABLE FOR 3.3 kV SYSTEM
CABLE SIZE
FULL LOAD
K FACTOR
PLATE kW
CURRENT
CURRENT
Efficiency
CABLE SIZE AS
sqrt. (t)/k
RATING
(in kVA)
(Amps.)
(Amps.)
A=Ish x
=FLC/k
BASED ON SELECTED
NAME
BASE
SL. PER BASE
FEEDER DESCRIPTION p.f. S/C CABLE SIZE REMARK
NO. CURRENT
CURRENT sq. mm.
sq. mm.
sq. mm.
19 MILL-F 0.7 0.9 525 833 145.80 147.41 150 0.63 231.42 3C-120 3C-150
20 MILL-G 0.7 0.9 525 833 145.80 147.41 150 0.63 231.42 3C-120 3C-150
21 MILL-H 0.7 0.9 525 833 145.80 147.41 150 0.63 231.42 3C-120 3C-150
22 MILL-J 0.7 0.9 525 833 145.80 147.41 150 0.63 231.42 3C-120 3C-150
23 MILL-K 0.7 0.9 525 833 145.80 147.41 150 0.63 231.42 3C-120 3C-150
24 MOTOR FEEDER TO SERVICE AIR COMPRESSOR-A 0.85 0.9 360 471 82.33 147.41 150 0.63 130.69 3C-50 3C-150
25 MOTOR FEEDER TO INSTRUMENT AIR COMPRESSOR-A 0.85 0.9 360 471 82.33 147.41 150 0.63 130.69 3C-50 3C-150
26 MOTOR FEEDER TO INSTRUMENT AIR COMPRESSOR-B 0.85 0.9 360 471 82.33 147.41 150 0.63 130.69 3C-50 3C-150
NOTES:
1 Equipment & their ratings are indicated on the basis of Electrical Single Line Diagram for Auxiliary Power Distribution (drawing no. PE-DG-209-565-E001). In case of any change in rating of any of the equipment listed
above, or addition of any loads, this table will be suitably amended.
2 In case of change of installation conditions of any feeder cable, the cable size/ type shall be checked for the new installation conditions and changed if required.
6 of 7
TABLE-B2: CABLE SELECTION TABLE FOR 3.3 kV GRADE CABLES (VFD SYSTEM)

VOLTAGE RATING
(Amps.) =AMPERE
AMPERE RATING
POWER FACTOR
A=Ish x sqrt. (t)/k
BASE CURRENT
EFFICIENCY
FACTOR (k)
DERATING
RATING/K
OVERALL
CABLE SIZE CABLE SIZE AS
AC/ DC
SELECTED
SL. BASED ON S/C PER LOAD
(V)
FEEDER DESCRIPTION CABLE SIZE REMARK
NO. CURRENT (sq. CURRENT
sq. mm.
mm.) sq. mm.
1 FROM VFD TRANSFORMER LV 2300 664 AC 147.41 150 0.83 800.59 2-1C-240/ph 2-1C-300/ph CABLE SIZES ARE
TERMINAL TO LCI PANEL BRIDGE SELECTED BASED ON
CUBICLE. VFD SYSTEM SUPPLIER
RECOMMENDATIONS.
SAME SIZE/
2 FROM LCI PANEL ADAPTOR CUBICLE 3300 730 DC 147.41 150 0.83 879.52 2-1C-300/P 3-1C-300/P CONFIGURATION HAS
TO DC REACTOR BEEN USED FOR
VARIOUS 500 MW UNITS
IN PROJECTS SUCH AS
3 FROM DC REACTOR TO LCI PANEL 3300 730 DC 147.41 150 0.83 879.52 2-1C-300/P 3-1C-300/P SIMHADRI, TALCHER,
ADAPTOR CUBICLE RIHAND &
RAMAGUNDAM ETC.
4 FROM LCI PANEL BRIDGE CUBICLE TO 2300 664 AC 147.41 150 0.83 800.59 2-1C-240/ph 2-1C-300/ph
MOTOR CIRCUIT BREAKER
5 FROM MOTOR CB TO MOTOR 2300 0.9 0.85 664 AC 147.41 150 0.83 800.59 2-1C-240/ph 2-1C-300/ph
TERMINALS
TABLE-C: CABLE SELECTION TABLE FOR 415 V SUPPLY FEEDERS (CABLES LAID IN AIR)

STEADY STATE VOLTAGE DROP (%)

CABLE SIZES FOR SUPPLY FEEDER LENGTH (M)
PERMISSIBLE 2.5%
Insulation
k factor
Size as per S/C
S.N.
STANDARD STANDARD Base Size as per Base

50 100 150 200 50 100 150 200
RATING(A) RATING(A)*0.9 current (mm 2) Current Current
1 1 0.90 NA 0.55 1.64 PVC 4C-2.5 (Cu) 4C-2.5 (Cu) 4C-2.5 (Cu) 4C-2.5 (Cu) 4C-2.5 (Cu) 0.14 0.29 0.43 0.57
3 5 4.50 NA 0.55 8.18 PVC 4C-2.5 (Cu) 4C-2.5 (Cu) 4C-2.5 (Cu) 4C-2.5 (Cu) 4C-10(Al) 0.71 1.43 2.14 1.20
4 10 9.00 NA 0.55 16.36 PVC 4C-2.5 (Cu) 4C-2.5 (Cu) 4C-10(Al) 4C-10(Al) 4C-10(Al) 1.43 1.20 1.80 2.40
2
5 15 13.50 NA 0.55 24.55 PVC 4C-10 (Al) 4C-10 (Al) 4C-10 (Al) 3.5C-25mm2[Al] 3.5C-25mm [Al] 0.90 1.80 1.07 1.43
2
6 20 18.00 NA 0.55 32.73 PVC 4C-10 (Al) 4C-10 (Al) 4C-10 (Al) 3.5C-25mm2[Al] 3.5C-25mm [Al] 1.20 2.40 1.43 1.91
7 25 22.50 NA 0.55 40.91 PVC 4C-16mm2[Al] 3.5C-25mm2[Al] 3.5C-25mm2[Al] 3.5C-25mm2[Al] 3.5C-25mm2[Al] 0.60 1.19 1.79 2.38
8 63 56.70 NA 0.55 103.09 PVC 3.5C-50mm2[Al] 3.5C-50mm2[Al] 3.5C-50mm2[Al] 3.5C-50mm2[Al] 3.5C-95mm2[Al] 0.82 1.64 2.47 1.74
9 100 90.00 NA 0.61 147.54 XLPE 3.5C-150mm2[Al] 3.5C-150mm2[Al] 3.5C-150mm2[Al] 3.5C-150mm2[Al] 3.5C-150mm2[Al] 0.49 0.99 1.48 1.97
2
10 125 112.50 NA 0.61 184.43 XLPE 3.5C-150mm [Al] 3.5C-150mm2[Al] 3.5C-150mm2[Al] 3.5C-150mm2[Al] 3.5C-150mm2[Al] 0.62 1.23 1.85 2.46
11 200 180.00 NA 0.61 295.08 XLPE 2

3.5C-240mm2[Al] 3.5C-240mm2[Al] 3.5C-240mm2[Al] 1C-400mm2[Al]/ph 0.66 1.31 1.97 2.16
3.5C-240mm [Al]
1C-400mm2[Al]-N
12 250 225.00 NA 0.61 368.85 XLPE 2 2 2 2 1C-400mm2[Al]/ph 0.82 1.64 2.46 2.32
3.5C-240mm (Al) 3.5C-240mm (Al) 3.5C-240mm (Al) 3.5C-240mm (Al)
1C-400mm2[Al]-N
1C-400mm2(Al)/ph 1C-400mm2(Al)/ph 1C-630mm2(Al)/ph 2-1C-400mm2(Al)/ph
13 400 360.00 NA 0.61 590.16 XLPE 1C-400mm2(Al)/ph 1C-400mm2((Al)-N 1C-400mm2((Al)-N 1C-400mm2((Al)-N 1C-400mm2((Al)-N
0.96 1.93 2.08 1.93
1C-630mm2(Al)/ph 1C-630mm2(Al)/ph 1C-630mm2(Al)/ph 2-1C-400mm2(Al)/ph 2-1C-630mm2(Al)/ph

14 630 567.00 300 0.83 683.13 XLPE 1.13 2.27 2.28 2.27
1C-400mm2(Al)-N 1C-400mm2(Al)-N 1C-400mm2(Al)-N 1C-400mm2(Al)-N 1C-400mm2(Al)-N
2-1C-400mm2(Al)/ph 2-1C-400mm2(Al)/ph 2-1C-400mm2(Al)/ph 2-1C-630mm2(Al)/ph 3-1C-630mm2(Al)/ph

15 800 720.00 300 0.83 867.47 XLPE 0.96 1.93 2.16 1.92
1C-400mm2(Al)-N 1C-400mm2((Al)-N 1C-400mm2((Al)-N 1C-400mm2((Al)-N 1C-400mm2((Al)-N

16 900 810.00 300 0.83 975.90 XLPE 1.09 2.17 2.43 2.16

17 1000 900.00 300 0.83 1084.34 XLPE 1.21 2.41 2.41 2.40

18 1600 1440.00 300 0.83 1734.94 XLPE 1.29 1.92 2.16 2.30
2-1C-400mm2(Al)-N 2-1C-400mm2(Al)-N 2-1C-400mm2(Al)-N 2-1C-400mm2(Al)-N 2-1C-400mm2(Al)-N
19 (*) 2086.81 300 0.83 2514.23 XLPE 4-1C-630mm2(Al)/ph 4-1C-630mm2(Al)/ph 4-1C-630mm2(Al)/ph 5-1C-630mm2(Al)/ph 7-1C-630mm2(Al)/ph 1.04 2.09 2.50 2.38
(*): 1500 kVA FEEDER FROM DG TO EMERGENCY BOARD

NOTES:
1 In the absence of final busbar ratings of various switchboards/ MCCs/ distribution boards/ supply feeders, the cable sizes have been calculated for 0.9 * rated busbar current (i.e. maximum loading of busbar). Cable sizes
for different switchboards/ MCCs/ ACDBs shall be chosen from the above based on the actual feeder length.However, the actual cable sizes will be deduced on the basis of actual current loading of each switchboard/
MCC/ ACDB.
2 In case of change of installation conditions of any feeder cable or length of feeder, the cable size/ type shall be checked for the new installation conditions/ feeder length and changed if required.
1 of 7
TABLE-D: CABLE SELECTION TABLE FOR 415 V SUPPLY FEEDERS (CABLES LAID IN TRENCH)

STEADY STATE VOLTAGE DROP (%)

PERMISSIBLE 2.5%
Size as
Insulation
k factor
STANDARD STANDARD per S/C Base Size as per Base
S.N.
50 100 150 200 50 100 150 200

RATING(A) RATING(A)*0.9 current Current Current
(mm2)
3 5 4.50 NA 0.49 9.18 PVC 4C-2.5 (Cu) 4C-2.5 (Cu) 4C-2.5 (Cu) 4C-2.5 (Cu) 4C-10(Al) 0.71 1.43 2.14 1.20
4 10 9.00 NA 0.49 18.37 PVC 4C-2.5 (Cu) 4C-2.5 (Cu) 4C-10(Al) 4C-10(Al) 4C-10(Al) 1.43 1.20 1.80 2.40
5 15 13.50 NA 0.49 27.55 PVC 4C-10 (Al) 4C-10 (Al) 4C-10 (Al) 3.5C-25 (Al) 3.5C-25 (Al) 0.90 1.80 1.07 1.43
2
6 20 18.00 NA 0.49 36.73 PVC 4C-10 (Al) 4C-10 (Al) 4C-10 (Al) 3.5C-25 (Al) 3.5C-25mm [Al] 1.20 2.40 1.43 1.91
2 2 2
7 25 22.50 NA 0.49 45.92 PVC 4C-16mm [Al] 3.5C-25mm2[Al] 3.5C-25mm2[Al] 3.5C-25mm [Al] 3.5C-25mm [Al] 0.60 1.19 1.79 2.38
2
8 63 56.70 NA 0.49 115.71 PVC 3.5C-95mm [Al] 3.5C-95mm2[Al] 3.5C-95mm2[Al] 3.5C-95mm2[Al] 3.5C-95mm2[Al] 0.43 0.87 1.30 1.74
2 1C-400mm2[Al]/ph
11 200 180.00 NA 0.54 333.33 XLPE 3.5C-240mm [Al] 3.5C-240mm2[Al] 3.5C-240mm2[Al] 3.5C-240mm2[Al] 0.66 1.31 1.97 2.16
1C-400mm2[Al]-N
2 2 2 2 2
1C-400mm [Al]/ph 1C-400mm [Al]/ph 1C-400mm [Al]/ph 1C-400mm [Al]/ph 1C-400mm [Al]/ph
12 250 225.00 NA 0.73 308.22 XLPE 0.60 1.21 1.81 2.32
1C-400mm2[Al]-N 1C-400mm2[Al]-N 1C-400mm2[Al]-N 1C-400mm2[Al]-N 1C-400mm2[Al]-N
1C-400mm2(Al)/ph 1C-400mm2(Al)/ph 1C-630mm2(Al)/ph 2-1C-400mm2(Al)/ph

13 400 360.00 NA 0.73 493.15 XLPE 1C-400mm2(Al)/ph 0.96 1.93 2.08 1.93
1C-400mm2((Al)-N 1C-400mm2((Al)-N 1C-400mm2((Al)-N 1C-400mm2((Al)-N
1C-630mm2(Al)/ph 1C-630mm2(Al)/ph 1C-630mm2(Al)/ph 2-1C-400mm2(Al)/ph 2-1C-630mm2(Al)/ph

14 630 567.00 300 0.73 776.71 XLPE 1.13 2.27 2.28 2.27

15 800 720.00 300 0.73 986.30 XLPE 0.96 1.93 2.16 1.92
1C-400mm2(Al)-N 1C-400mm2((Al)-N 1C-400mm2((Al)-N 1C-400mm2((Al)-N 1C-400mm2((Al)-N

16 900 810.00 300 0.73 1109.59 XLPE 1.09 2.17 2.43 2.16

17 1000 900.00 300 0.73 1232.88 XLPE 0.90 1.80 1.80 2.40

18 1600 1440.00 300 0.73 1972.60 XLPE 0.96 1.92 2.16 2.30
2-1C-400mm2(Al)-N 2-1C-400mm2(Al)-N 2-1C-400mm2(Al)-N 2-1C-400mm2(Al)-N 2-1C-400mm2(Al)-N
NOTES:
1 In the absence of final busbar ratings of various switchboards/ MCCs/ distribution boards/ supply feeders, the cable sizes have been calculated for 0.9 * rated busbar current (i.e. maximum loading of busbar). Cable
sizes for different switchboards/ MCCs/ ACDBs shall be chosen from the above based on the actual feeder length.However, the actual cable sizes will be deduced on the basis of actual current loading of each
switchboard/ MCC/ ACDB.
2 of 7
TABLE E: CABLE SELECTION TABLE FOR 415 V MOTOR FEEDERS (CABLES LAID IN AIR)
2 X 500 VINDHYACHAL STPP, STAGE-III

STEADY STATE DROP TRANSIENT STATE DROP

CABLE SIZES FOR MOTOR FEEDER LENGTH(IN M.)
PERMISSIBLE 2.5% PERMISSIBLE 10%
Power Factor
x Efficiency
Size as per
s/c current
Efficiency
Insulation
Uprated
Current
k factor
current
Power
Factor
Rated
[Amp]
FROM Size as per Base
S.N.
Sinφ
TO [kW] 50 100 150 200 50 100 150 200 50 100 150 200
[kW] Current
1 0.01 1.00 0.70 0.71 0.74 0.52 2.69 2.5 0.55 4.88 3C-2.5mm2[Cu] PVC 3C-2.5mm2[Cu] 3C-2.5mm2[Cu] 3C-2.5mm2[Cu] 3C-2.5mm2[Cu] 0.35 0.71 1.06 1.41 1.12 2.23 3.35 4.47
3 2.01 3.70 0.84 0.54 0.84 0.71 7.30 2.5 0.55 13.26 3C-2.5mm2[Cu] PVC 3C-2.5mm2[Cu] 3C-2.5mm2[Cu] 3C-10mm2[Al] 3C-10mm2[Al] 1.15 2.29 1.44 1.92 3.03 6.07 3.93 5.25
5 5.51 7.50 0.84 0.54 0.84 0.71 14.79 2.5 0.55 26.89 3C-10mm2[Al] PVC 3C-10mm2[Al] 3C-10mm2[Al] 3C-25mm2[Al] 3C-25mm2[Al] 0.97 1.95 1.16 1.55 2.66 5.32 3.42 4.56
15 45.10 55.00 0.85 0.53 0.95 0.81 94.76 2.5 0.61 155.34 3C-150mm2[Al] XLPE 3C-150mm2[Al] 3C-150mm2[Al] 3C-150mm2[Al] 3C-150mm2[Al] 0.52 1.04 1.55 2.07 2.10 4.19 6.29 8.38
2 2 2 2
19 75.10 90.00 0.85 0.53 0.95 0.81 155.06 2.5 0.61 254.20 3C-150mm [Al] XLPE 3C-150mm [Al] 3C-150mm [Al] 3C-240mm [Al] 2-3C-150mm2[Al] 0.85 1.70 1.69 1.70 3.43 6.86 8.09 6.86
20 90.10 110.00 0.85 0.53 0.95 0.81 189.52 2.5 0.61 310.69 3C-240mm2[Al] XLPE 3C-240mm2[Al] 3C-240mm2[Al] 3C-240mm2[Al] 2-3C-150mm2[Al] 0.69 1.38 2.07 2.07 3.30 6.59 9.89 8.38
21 110.10 125.00 0.85 0.53 0.95 0.81 215.36 2.5 0.61 353.05 3C-240mm2[Al] XLPE 3C-240mm2[Al] 3C-240mm2[Al] 2-3C-150mm2[Al] 2-3C-150mm2[Al] 0.78 1.57 1.77 2.36 3.75 7.49 7.15 9.53
22 125.10 145.00 0.85 0.53 0.95 0.81 249.82 2.5 0.61 409.54 2-3C-150mm2[Al] XLPE 2-3C-150mm2[Al] 2-3C-150mm2[Al] 2-3C-150mm2[Al] 2-3C-240mm2[Al] 0.68 1.37 2.05 1.82 2.76 5.53 8.29 8.69
2 2 2 2 2
23 145.10 160.00 0.85 0.53 0.95 0.81 275.66 2.5 0.61 451.91 2-3C-150mm [Al] XLPE 2-3C-150mm [Al] 2-3C-150mm [Al] 2-3C-150mm [Al] 2-3C-240mm [Al] 0.75 1.51 2.26 2.00 3.05 6.10 9.15 9.59
NOTES:
1 The cable size for any motor shall be chosen from the above table depending upon the rating of the motor and length of feeder.
3 of 7
TABLE F: CABLE SELECTION TABLE FOR 415 V MOTOR FEEDERS (CABLES LAID IN COVERED TRENCH WITH RESTRICTED AIR CIRCULATION)

STEADY STATE DROP TRANSIENT STATE DROP

CABLE SIZES FOR MOTOR FEEDER LENGTH(IN M.)
PERMISSIBLE 2.5% PERMISSIBLE 10%
Power Factor
x Efficiency
Size as per
s/c current
Insulation
Efficiency
Uprated
Current
k factor
current
Power
Factor
Rated
[Amp]
FROM Size as per Base
S.N.
Sinφ
TO [kW] 50 100 150 200 50 100 150 200 50 100 150 200
[kW] Current
2 2 2 2
2 1.01 2.00 0.84 0.54 0.84 0.71 3.94 2.5 0.49 8.05 3C-2.5mm [Cu] PVC 3C-2.5mm [Cu] 3C-2.5mm [Cu] 3C-2.5mm [Cu] 3C-2.5mm2[Cu] 0.62 1.24 1.86 2.48 1.64 3.28 4.92 6.56
2
9 15.10 18.50 0.84 0.54 0.84 0.71 36.48 2.5 0.49 74.44 3C-50mm [Al] PVC 3C-50mm2[Al] 3C-50mm2[Al] 3C-50mm2[Al] 3C-50mm2[Al] 0.52 1.05 1.57 2.10 1.66 3.33 4.99 6.66
2 2 2 2
19 75.10 90.00 0.85 0.53 0.95 0.81 155.06 2.5 0.54 287.15 3C-150mm [Al] XLPE 3C-150mm [Al] 3C-150mm [Al] 3C-240mm [Al] 2-3C-150mm2[Al] 0.85 1.70 1.69 1.70 3.43 6.86 8.09 6.86
20 90.10 110.00 0.85 0.53 0.95 0.81 189.52 2.5 0.54 350.96 3C-240mm2[Al] XLPE 3C-240mm2[Al] 3C-240mm2[Al] 3C-240mm2[Al] 2-3C-150mm2[Al] 0.69 1.38 2.07 2.07 3.30 6.59 9.89 8.38
2 2 2 2
21 110.10 125.00 0.85 0.53 0.95 0.81 215.36 2.5 0.54 398.82 3C-240mm [Al] XLPE 3C-240mm [Al] 3C-240mm [Al] 2-3C-150mm [Al] 2-3C-150mm2[Al] 0.78 1.57 1.77 2.36 3.75 7.49 7.15 9.53
22 125.10 145.00 0.85 0.53 0.95 0.81 249.82 2.5 0.54 462.63 2-3C-150mm2[Al] XLPE 2-3C-150mm2[Al] 2-3C-150mm2[Al] 2-3C-150mm2[Al] 2-3C-240mm2[Al] 0.68 1.37 2.05 1.82 2.76 5.53 8.29 8.69
2 2 2 2
23 145.10 160.00 0.85 0.53 0.95 0.81 275.66 2.5 0.54 510.49 2-3C-150mm [Al] XLPE 2-3C-150mm [Al] 2-3C-150mm [Al] 2-3C-150mm [Al] 2-3C-240mm2[Al] 0.75 1.51 2.26 2.00 3.05 6.10 9.15 9.59
NOTES:
1 The cable size for any motor shall be chosen from the above table depending upon the rating of the motor and length of feeder.
4 of 7
TABLE-G: CABLE SELECTION TABLE FOR 240 V AC SUPPLY FEEDERS (CABLES LAID IN AIR)

STEADY STATE VOLTAGE DROP (V)

PERMISSIBLE: 10 V
Insulation
Size as per
k factor
LOAD Uprated Size as per Base
S.N.
S/C current 25 50 75 100 25 50 75 100

CURRENT (A) Current Current
(mm2)
1 1 NA 0.55 1.82 PVC 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 0.44 0.89 1.33 1.78
2 2 2 2
2 5 NA 0.55 9.09 PVC 2C-2.5mm2[Cu] 2C-2.5mm [Cu] 2C-2.5mm [Cu] 2C-2.5mm [Cu] 2C-2.5mm [Cu] 2.22 4.45 6.67 8.89
3 10 NA 0.55 18.18 PVC 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-10mm2[Al] 2C-10mm2[Al] 4.45 8.89 5.55 7.40
4 15 NA 0.55 27.27 PVC 2C-10mm2[Al] 2C-10mm2[Al] 2C-10mm2[Al] 2C-10mm2[Al] 2C-25mm2[Al] 2.78 5.55 8.33 4.32
NOTES:
1 The cable size for any load shall be chosen from the above table depending upon the rating of the load and length of feeder.
5 of 7
TABLE-H: CABLE SELECTION TABLE FOR 240 V AC SUPPLY SYSTEM (CABLES LAID IN TRENCH WITH RESTRICTED AIR CIRCULATION)

STEADY STATE VOLTAGE DROP (V)

PERMISSIBLE: 10 V
Insulation
Size as per
k factor
LOAD Uprated Size as per Base
S.N.
S/C current 25 50 75 100 25 50 75 100

CURRENT (A) Current Current
(mm2)
1 1 NA 0.49 2.04 PVC 2C-2.5mm2[Cu] 2

2C-2.5mm [Cu]
2
2C-2.5mm [Cu]
2
2C-2.5mm [Cu] 2C-2.5mm [Cu]
2
0.44 0.89 1.33 1.78
2 5 NA 0.49 10.20 PVC 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2

2C-2.5mm [Cu]
2
2C-2.5mm [Cu] 2C-2.5mm [Cu]
2
2.22 4.45 6.67 8.89
2 2
3 10 NA 0.49 20.41 PVC 2C-2.5mm2[Cu] 2C-2.5mm [Cu] 2C-2.5mm [Cu] 2C-10mm2[Al] 2C-10mm2[Al] 4.45 8.89 5.55 7.40
NOTES:
6 of 7
TABLE I: CABLE SELECTION TABLE FOR 220 V DC SYSTEM (CABLES LAID IN AIR)

CABLE SIZES FOR SUPPLY FEEDER LENGTH (M) STEADY STATE DROP IN VOLTS
VOLTAGE DROP
PERMISSIBLE
Insulation
LOAD Size as
Uprated Size as per Base
S.N.
(V)
10
CURRENT(A per s/c k factor 10 25 50 100 150 200 500 800 1000 1200 1500 3000 25 50 100 150 200 500 800 1000 1200 1500 3000
Current Current
) current
CABLE SIZES FROM DCDB TO LOAD
1 1 2.5 0.55 1.82 PVC 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-10mm2[Al] 2C-25mm2[Al] 2C-25mm2[Al] 2C-25mm2[Al] 2C-70mm2[Al] 2C-70mm2[Al] 4 0.18 0.44 0.89 1.78 2.67 3.56 3.70 2.30 2.88 3.46 1.60 3.19
2 2 2.5 0.55 3.64 PVC 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-10mm2[Al] 2C-10mm2[Al] 2C-25mm2[Al] 2C-70mm2[Al] 2C-70mm2[Al] 2C-70mm2[Al] 2C-70mm2[Al] 2C-120mm2[Al] 4 0.36 0.89 1.78 3.56 2.22 2.96 2.88 1.70 2.13 2.55 3.19 3.65
3 5 2.5 0.55 9.09 PVC/ XLPE 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-10mm2[Al] 2C-10mm2[Al] 2C-25mm2[Al] 2C-25mm2[Al] 2C-70mm2[Al] 2C-120mm2[Al] 2C-120mm2[Al] 2C-120mm2[Al] 1C-400mm2[Al] 1C-400mm2[Al] 4 0.89 2.22 1.85 3.70 2.16 2.88 2.66 2.43 3.04 3.65 1.53 3.06
4 10 2.5 0.55 18.18 PVC/ XLPE 2C-2.5mm2[Cu] 2C-2.5mm2[Cu] 2C-10mm2[Al] 2C-10mm2[Al] 2C-25mm2[Al] 2C-70mm2[Al] 2C-70mm2[Al] 2C-120mm2[Al] 1C-400mm2[Al]/P 1C-400mm2[Al]/P 1C-400mm2[Al]/P 1C-400mm2[Al]/P 1C-630mm2[Al]/P 4 1.78 1.85 3.70 2.88 1.60 2.13 3.04 1.63 2.04 2.45 3.06 3.90
5 16 2.5 0.55 29.09 PVC/ XLPE 2C-10mm2[Al] 2C-10mm2[Al] 2C-10mm2[Al] 2C-25mm2[Al] 2C-70mm2[Al] 2C-70mm2[Al] 2C-70mm2[Al] 1C-400mm2[Al]/P 1C-400mm2[Al]/P 1C-400mm2[Al]/P 1C-400mm2[Al]/P 1C-630mm2[Al]/P 2-1C-630mm2[Al]/P 4 1.18 2.96 2.30 1.70 2.55 3.40 1.63 2.61 3.26 3.92 3.12 3.12
6(*) 20 2.5 0.55 36.36 PVC/ XLPE 2C-10mm2[Al] 2C-10mm2[Al] 2C-10mm2[Al] 2C-25mm2[Al] 2C-70mm2[Al] 2C-70mm2[Al] 2C-120mm2[Al] 1C-400mm2[Al]/P 1C-400mm2[Al]/P 1C-630mm2[Al]/P 1C-630mm2[Al]/P 1C-630mm2[Al]/P 2-1C-630mm2[Al]/P 4 1.48 3.70 2.88 2.13 3.19 2.43 2.04 3.26 2.60 3.12 3.90 3.90
7 25 2.5 0.55 45.45 PVC/ XLPE 2C-10mm2[Al] 2C-10mm2[Al] 2C-25mm2[Al] 2C-25mm2[Al] 2C-70mm2[Al] 2C-70mm2[Al] 2C-120mm2[Al] 1C-400mm2[Al]/P 1C-630mm2[Al]/P 1C-630mm2[Al]/P 1C-630mm2[Al]/P 2-1C-400mm2[Al]/P 3-1C-630mm2[Al]/P 4 1.85 1.80 3.60 2.66 3.99 3.04 2.55 2.60 3.25 3.90 3.83 3.25
8 35 2.5 0.55 63.64 PVC/ XLPE 2C-25mm2[Al] 2C-25mm2[Al] 2C-25mm2[Al] 2C-70mm2[Al] 2C-70mm2[Al] 2C-120mm2[Al] 1C-400mm2[Al]/P 1C-400mm2[Al]/P 1C-630mm2[Al]/P 2-1C-400mm2[Al]/P - - - 4 1.01 2.52 1.86 3.72 3.19 1.43 3.57 3.64 3.57 - - -
9 50 2.5 0.55 90.91 PVC/ XLPE 2C-70mm2[Al] 2C-70mm2[Al] 2C-70mm2[Al] 2C-70mm2[Al] 2C-120mm2[Al] 1C-400mm2[Al]/P 1C-400mm2[Al]/P 1C-630mm2[Al]/P 2-1C-630mm2[Al]/P - - - - 4 0.53 1.33 2.66 3.04 1.53 2.04 3.25 2.60 - - - -
10 80 2.5 0.55 145.45 PVC/ XLPE 2C-70mm2[Al] 2C-70mm2[Al] 2C-70mm2[Al] 2C-120mm2[Al] 1C-400mm2[Al]/P 1C-400mm2[Al]/P 1C-400mm2[Al]/P - - - - - - 4 0.85 2.13 2.43 1.63 2.45 3.26 - - - - - -
11 100 2.5 0.55 181.82 PVC/ XLPE 2C-120mm2[Al] 2C-120mm2[Al] 2C-120mm2[Al] 2C-120mm2[Al] 1C-400mm2[Al]/P - - - - - - - - - 0.61 1.52 3.04 2.04 - - - - - - - -
CABLE SIZES FOR BATTERY TO DCDB & CHARGER TO DCDB
12 400 2.5 0.83 481.93 XLPE 1C-400mm2[Al]/P 1C-400mm2[Al]/P 1C-630mm2[Al]/P 2-1C-630mm2[Al]/P 4-1C-630mm2[Al]/P - - - - - - - - 1.66 0.82 1.30 1.30 1.30 - - - - - - - -
13 850 300.0 0.83 1024.10 XLPE 2-1C-400mm2[Al]/P 2-1C-400mm2[Al]/P 2-1C-630mm2[Al]/P 4-1C-630mm2[Al]/P 8-1C-630mm2[Al]/P - - - - - - - - 1.66 0.87 1.38 1.38 1.38 - - - - - - - -
NOTES:
1 Cables of sizes 150 sq. mm. and above are with XLPE insulation, while all others are with PVC insulation.
4 (*): An actual load current of 20 A is considered for cable sizing of 32 A feeders required to be provided for non-Main Plant Turnkey package areas for which 220 V DC feeders are to be provided from station 220 V DC system.
1 of 1
ANNEXURE- ‘B’:
CABLE DATA
ANNEXURE- ‘C’:
SUMMARY SHEET
Design Calculations For Cable Sizing & Selection Doc. No. PE-DC-209-507-E003
Rev No. 0
January 21, 2004
SUMMARY SHEET:
POWER/ CONTROL CABLE SIZES FINALISED FOR THE PROJECT
11/ 11 kV, XLPE INSULATED POWER 3.3/ 3.3 kV, XLPE 1.1 kV, XLPE 1.1 kV, PVC INSULATED POWER CABLES 1.1 kV, PVC INSULATED CONTROL
CABLES INSULATED INSULATED POWER CABLES
POWER CABLES CABLES
UNARMOURED, ARMOURED, UNARMOURED, UNARMOURED, Al. UNARMOURED, ARMOURED, UNARMOURED, ARMOURED, UNARMOURED, ARMOURED,
Al. CONDUCTOR Al. CONDUCTOR Al. CONDUCTOR CONDUCTOR Al CONDUCTOR Al CONDUCTOR Cu CONDUCTOR Cu CONDUCTOR Cu CONDUCTOR Cu CONDUCTOR
1C-500 3C-150 1C-300 1C-630 2C-2.5 3.5C-25 2C-2.5 5C-6 2C-1.5 2C-2.5
1C-150 1C-150 1C-400 2C-10 3.5C-50 3C-2.5 3C-1.5 5C-2.5
3C-150 3C-150 3C-240 2C-25 4C-2.5 5C-1.5 7C-2.5
3C-150 2C-70 7C-1.5 14C-2.5
3.5 C-240 2C-120 10C-1.5 16C-2.5
3.5 C-150 3C-10 12C-1.5
3C-25 14C-1.5
3C-50 19C-1.5
3C-95 27C-1.5
3.5C-25 2C-2.5
3.5C-50 3C-2.5
3.5C-95 4C-2.5
4C-10 5C-2.5
10C-2.5
14C-2.5
SHT 1 OF 1

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NATIONAL THERMAL POWER CORPORATION LTD.

2 x 500MW VINDHYACHAL STPP STAGE-III

DESIGN CALCULATIONS FOR CABLE SIZING AND SELECTION

NTPC DOC. NO. 2240-108-23PE-PVE-K-026

BHEL DOC. NO. PE-DC-209-507-E003

BHARAT HEAVY ELECTRICALS LIMITED

S. NO. CONTENTS NO. OF SHEETS

2 ANNEXURE-A: SELECTION TABLE FOR CABLE SIZES

TABLE-A: CABLE SELECTION TABLE FOR 11 kV SYSTEM 4

TABLE-B1: CABLE SELECTION TABLE FOR 3.3 kV SYSTEM 2

TABLE-G: CABLE SELECTION TABLE FOR 240 V AC SUPPLY SYSTEM: CABLES 1

TABLE-H: CABLE SELECTION TABLE FOR 240 V AC SUPPLY SYSTEM: CABLES 1

TABLE-I: CABLE SELECTION TABLE FOR 220 V DC SYSTEM: 1

3 ANNEXURE-B: CABLE DATA 21

4 ANNEXURE-C: SUMMARY SHEET (CABLE SIZES FINALISED FOR THE PROJECT) 1

This document covers the following:

3.0 TYPE OF CABLES SELECTED

a) 11kV & 3.3 kV Power Cables

b) 1.1 kV Power Cables (sizes 150 sq. mm. and above)

c) 1.1 kV Power Cables (below 150 sq. mm.)

3.2 Standards applicable:

4.1 DESIGN CONSIDERATIONS: POWER CABLES

(a) 11 kV Transformer feeders:

(b) 11 kV Motor feeders:

Power Factor for CW pump motor= 0.75

(c) 3.3 kV Transformer feeders:

(d) 3.3 kV Motor feeders:

Current ratings corresponding to the full load current of motor.

(e) 3.3 kV feeders (VFD system)

Efficiency for ID fan= 0.85

(f) 415 V Supply feeders:

(g) 415 V Motor feeders:

(h) 240 V AC feeders:

(i) 220 V DC feeders:

(j) Voltage drop limits considered are as under:

i) 415 V AC Supply Feeders

iii) 240 V AC Supply Feeders 10 V

iv) 220 V DC Feeders

4.2 DESIGN CONSIDERATIONS: CONTROL CABLES

4.2.2 Minimum no. of spare cores in control cables shall be as follows:

4.3 DESIGN INPUT DATA

(a) Design ambient temperature: 50 °C

(b) Fault current for 11 kV & 3.3 kV systems: 40 kA RMS

(c) Fault current for 415V systems: 50 kA RMS

(e) Annexure-B: Cable Technical Data

- Resistances & Reactances-CABLE CATALOGUE OF UNIVERSAL CABLES LIMITED

Table-62 Approximate AC resistance of conductor (Ohm/ km) at maximum operating conductor

- Derating factors for installation conditions-CABLE CATALOGUE OF UNIVERSAL CABLES LIMITED

All 11 kV and 3.3 kV feeders are circuit breaker protected.

Cables are rated for laying in the following conditions:

(2) Group derating factor (K2)

No. of cores Arrangement of cables K2 Table ref.

Overall derating factor = K1 x K2

(ii) Cables laid directly in ground

(2) Group derating factor (K4)=

No. of cores Arrangement of cables K4 Table ref.

4.3.2 DESIGN INPUTS FOR CABLE SIZING FOR 415 V SYSTEM

Fault current Ish = 50 kA RMS

Minimum cross-sectional area to withstand Short circuit current (A)= Ish.SQRT(t)/k

where k is a constant (for Al. conductor XLPE insulation) 0.094

Therefore, A (Al. conductor XLPE insulation)= 184.26 mm2

(i) Cables in air

Overall derating factor K