Doc No.

: MPPL-A1693/E-334A

PROJECT TITLE NTPC Doc No.: Rev. No.

0 SYSTEM PACKAGE FOR FAULT LEVEL 4340-162(A)-PVE-U-004A 2
KAHALGAON THERMAL POWER PROJECT CALCULATIONS MECGALE Doc No. Date
MECGALE ( STAGE – I, UNIT # 3 & 4, 2 x 210 MW ) (1600KVA TRANSFORMER) MPPL-A1693/E-334A 29.09.19

A FAULT LEVELS WITH RATED VOLTAGES AND NORMAL IMPEDANCE OF 1600KVA TRANSFORMERS
1.0 SYSTEM DATA
i Incoming Voltage = 6.6 KV
ii Fault Current = 40 KA
iii Therefore, Fault level at 6.6KV Bus = 457.248 MVA at 6.6KV
iv Fault Clearing Time = 4 Cycles (Max)
= 120 mSec (Max)
v Total Highest Rating motors provided in 6.6KV MCC & 415V PMCC 6.0 Nos
a) Rating = 425 KW (2W+1S)
b) Full Load Current = 46.0 Amp (Marathon data sht)
c) Full Load Efficiency = 95 % (Marathon data sht)
d) Full Load Power Factor = 0.85 lag (Marathon data sht)
e) Rating = 160 KW (2W+1S)
f) Full Load Current = 267.0 Amp (Siemens data sht)
g) Full Load Efficiency = 95.9 % (Siemens data sht)
h) Full Load Power Factor = 0.87 lag (Siemens data sht)
i) K Factor for motor = 1 (Rated >750KW)
j) K Factor for motor = 1.2 (Rated <750KW)
vi 6.6KV, 425KW motor starting current at rated voltage = 6 times FLC (Marathon data sht)
415V, 160KW motor starting current at rated voltage = 7.69663 times FLC (Siemens data sht)
vii Considering 1 out of 2 incomers are on, max possible load on incomer = (425x2+160x2)KW
viii 6.6/0.433KV Transformer rating(TR-1/ TR-2) = 1.6 MVA (2 Nos) (1W+1S)
ix 11/0.433KV Transformer impedance(TR-1/ TR-2) on principal tap = 8% (Max)

2.0 FORMULE USED

2 2
i Calculated impedance for 3 core cable (ZC) = SQRT(R +X ) Ohms
Where R = AC resistance in Ohms at 900C
X = Reactance in Ohms at 50HZ for 3 core cable
Impedance for 3 core cable after corrections for site conditions (Z) = 1.1 X ZC Ohms

ii p u impedance = (BaseMVA) / Fault MVA

iii p u impedance = (Z * BaseMVA) / KV2
= (Z * BaseMVA) / Rated MVA
iv Fault MVA contribution by running motor = (1.2 * Running load of motor in MVA)
Fault MVA contribution by running 425KW motor = (6.0 * Running load of motor in MVA)
Fault MVA contribution by running 160KW motor = (7.2 * Running load of motor in MVA)
v 425KW rating motor starting current at 100% of rated voltage = 6 times FLC
= 6 times FLC
3.0 CALCULATIONS
i Minimum crossectional area required to carry fault current
a) Fault Current at 6.6KV = 40 KA
b) Fault Clearing Time (Max) considered for cable sizing = 0.12 Sec
c) Conductor temp prior to short circuit = 90 Deg C
d) Max short circuit conductor temeperature = 250 Deg C
e) Ik = 0.094A/ (Sqrt t)
Where
Ik = Fault Current in KA
A = Area of Aluminium Conductor in Sqmm
t = Fault clearing time in Sec
Therefore, min area of Al Conductor in Sqmm reqd = 147
Cables provided = 1Run of 3Cx240Sqmm size
ii 3C x 240Sq mm, AL conductor XLPE insulated 6.6KV(UE) grade cable
a) AC resistance at 90 degree centigrade( R ) = 0.162 Ohms/KM
b) Reactance at 50HZ for 3 core cable ( X ) = 0.071 Ohms/KM
c) Calculated impedance for 3 core cable (ZC) = 0.177 Ohms/KM
d) Impedance for 3 core cable after corrections for site conditions (Z) = 0.195 Ohms/KM

Mecgale Page No. : 2 of 6 NTPC - KhSTPP

 Doc No. : MPPL-A1693/E-334A

PROJECT TITLE NTPC Doc No.: Rev. No.

0 SYSTEM PACKAGE FOR FAULT LEVEL 4340-162(A)-PVE-U-004A 2
KAHALGAON THERMAL POWER PROJECT CALCULATIONS MECGALE Doc No. Date
MECGALE ( STAGE – I, UNIT # 3 & 4, 2 x 210 MW ) (1600KVA TRANSFORMER) MPPL-A1693/E-334A 29.09.19

iii 3C x 150Sq mm, AL conductor XLPE insulated 6.6KV(E) grade cable

a) AC resistance at 90 degree centigrade = 0.265 Ohms/KM
b) Reactance at 50HZ for 3 core cable = 0.072 Ohms/KM
c) Calculated impedance for 3 core cable (ZC) = 0.275 Ohms/KM
d) Impedance for 3 core cable after corrections for site conditions (Z) = 0.302 Ohms/KM

iv CONSIDER BASE MVA = 5.000 MVA

v CONSIDER BASE KV = 6.600 KV
vi Base Current = 0.437399398 KA
vii Base Impedance = 8.712000000 Ohms
viiiImpedance of Transformer = (1W+1S)
Rated Capacity of Transformer = 1.600 MVA
No-load Primary Voltage of Transformer = 6.600 KV
No-load Secondary Voltage of Transformer = 0.433 KV
Z Transformer = 0.080 pu
Tolerance in Impedence = 0.9
Minimum Tap at = 0.95 (of rated voltage)
Zmin of Transformer = 0.068 pu
Z Transformer at 6.6KV = 0.068400000 pu
ix p u impedance of utility = 0.010934985 pu
p u impedance of utility at base voltage (Zs) = 0.010934985 pu
x p u impedance of 1.6MVA transformer at base voltage(Ztr) = 0.21375 pu
xi p u impedance of 3C x 240 XLPE cable
Voltage level = 6.6 KV
Length = 250 Mtrs
= 0.00558320
No of runs in parallel = 1
Therefore, p u impedance of 1-3C x 240 XLPE cable(C11/C12) = 0.005583196
xii p u impedance of 3C x 150 XLPE cable
Voltage level = 6.6 KV
Length = 65 Mtrs
= 0.00225286
No of runs in parallel = 1
Therefore, p u impedance of 1-3C x 150 XLPE cable(C21/ C22) = 0.002252860
Total pu Impedance (Ztotal) = (Zs + Ztr + Zc) = 0.230268181
xiii Fault MVA contribution from running motors
425KW Compressors = 6315.789 KVA
160KW Compressors = 2951.975 KVA
Total load contribution = 9267.765 KVA
= 9.268 MVA
3.1 FAULT LEVEL CALCULATIONS
i Fault level at 6.6KV Switch Board bus at rated voltage due to utility = 302.70 MVA
Fault level contribution due to running motors = 9.268 MVA
Total Fault level at 6.6KV Switch Board bus at rated voltage = 311.965 MVA
Therefore, fault level at 6.6KV Sw Board bus with +10% voltage variation = 343.16 MVA (Max)
However, 6.6KV Sw Board designed to withstand 40KA fault level for 1.0Sec at 6.6KV, 50Hz.
ii Fault level at 415V PMCC bus at rated voltage = 21.71 MVA
Fault level contribution due to running motors = 9.268 MVA
Total Fault level at 415V PMCC bus at rated voltage = 30.982 MVA
Therefore, fault level at 415V PMCC bus with +10% voltage variation = 34.08 MVA (Max)
However, PMCC designed to withstand 35MVA fault level for 1.0Sec at 415V, 50Hz.

iv p u impedance of 425KW running motor & cable = 9.50225286

p u impedance of 2 nos 425KW running motors & cable = 4.75112643
v p u impedance of 425KW motor being started & cable = 1.58370881
vi p u impedance of 160KW running motor = 26.07281250

Mecgale Page No. : 3 of 6 NTPC - KhSTPP

 Doc No. : MPPL-A1693/E-334A

PROJECT TITLE NTPC Doc No.: Rev. No.

0 SYSTEM PACKAGE FOR FAULT LEVEL 4340-162(A)-PVE-U-004A 2
KAHALGAON THERMAL POWER PROJECT CALCULATIONS MECGALE Doc No. Date
MECGALE ( STAGE – I, UNIT # 3 & 4, 2 x 210 MW ) (1600KVA TRANSFORMER) MPPL-A1693/E-334A 29.09.19

p u impedance of 160KW running motor at base voltage = 0.59854941

p u impedance of 2 nos 160KW running motors at base voltage = 0.29927471
p u impedance of 2 nos 160KW running motors & Tr at base voltage = 0.51302471
vii p u impedance of 1nos 425KW+2 nos 160KW running motors = 0.48674542
vi p u impedance of all motor being running+started = 0.37231589
vii Total p u impedance of system under transient condition = 0.38883407
Voltage drops at various system components when 425KW rated motor is started & 1x425KW+2X160KW rated motors VOLT
3.2
are running, incoming voltage is 6.6KV DROP

% voltage drop at 6.6KV utility = 2.81224968 186

% voltage drop in cable C11 = 1.43588148 95
% voltage drop in cables and motors (Transformer, TR-1) = 95.75186884 6320
% voltage drop in cable feeding to 425KW motor being started, C21 = 0.13601565 9
% voltage drop in 425KW motor being started = 95.61585319 6311

Voltage drops at various system components under steady state condition ie when 2x425KW+2x160KW rated motors
3.3
are running, incoming voltage is 6.6KV
p u impedance of 425KW running motor & cable = 9.50225286
p u impedance of 2 nos 425KW running motors & cable = 4.75112643
p u impedance of 2 nos 160KW running motors & Tr at base voltage = 0.51302471
p u impedance of all running motors = 0.46302722
Total p u impedance of system under steady state condition = 0.47954540
VOLT
DROP
% voltage drop at 6.6KV utility = 2.28028149 150
% voltage drop in cable C11 = 1.16426859 77
% voltage drop in cables and motors (Transformer, TR-1) = 96.55544992 6373
% voltage drop in cable C21 = 0.02288661 2
% voltage drop in 425KW motor running = 96.55544992 6373

Voltage drops at various system components when 425KW rated motor is started & 2x425KW+2X160KW rated motors VOLT
3.4
are running, incoming voltage is 6.6KV DROP

p u impedance of 425KW running motor & cable = 9.50225286

p u impedance of 2 nos 425KW running motors & cable = 4.75112643
p u impedance of 425KW motor being started = 1.58370881
p u impedance of 160KW running motor = 26.07281250
p u impedance of 160KW running motor at base voltage = 0.59854941
p u impedance of 2 nos 160KW running motors at base voltage = 0.29927471
p u impedance of 2 nos 160KW running motors & Tr at base voltage = 0.51302471
p u impedance of 2nos 425KW+2 nos 160KW running motors = 0.46302722
p u impedance of all motor being running+started = 0.35827790
Total p u impedance of system under transient condition = 0.37479608
% voltage drop at 6.6KV utility = 2.91758253 193
% voltage drop in cable C11 = 1.48966244 98
% voltage drop in cables and motors (Transformer, TR-1) = 95.59275503 6309
% voltage drop in cable feeding to 425KW motor being started, C21 = 0.13578963 9
% voltage drop in 425KW motor being started = 95.45696540 6300

Voltage drops at various system components when 160KW rated motor is started & 2x425KW+2X160KW rated motors VOLT
3.5
are running, incoming voltage is 6.6KV DROP

p u impedance of 425KW running motor = 9.50225286

p u impedance of 2 nos 425KW running motors = 4.75112643
p u impedance of 160KW running motor = 26.07281250
p u impedance of 160KW running motor at base voltage = 0.59854941
p u impedance of 160KW motor being started at base voltage = 0.07776773
p u impedance of 2 nos 160KW running motors at base voltage = 0.29927471
p u impedance of 2 nos 425KW running motors & Tr at base voltage = 0.20454754
p u impedance of 2 nos 160KW running motors +1 no 160KW starting motor = 0.06172758
p u impedance of all motor being running+started = 0.26627512
Total p u impedance of system under transient condition = 0.28279330
% voltage drop at 6.6KV utility = 3.86677653 255

Mecgale Page No. : 4 of 6 NTPC - KhSTPP

 Doc No. : MPPL-A1693/E-334A

PROJECT TITLE NTPC Doc No.: Rev. No.

0 SYSTEM PACKAGE FOR FAULT LEVEL 4340-162(A)-PVE-U-004A 2
KAHALGAON THERMAL POWER PROJECT CALCULATIONS MECGALE Doc No. Date
MECGALE ( STAGE – I, UNIT # 3 & 4, 2 x 210 MW ) (1600KVA TRANSFORMER) MPPL-A1693/E-334A 29.09.19

% voltage drop in cable C11 = 1.97430293 130

% voltage drop in cables and motors (Transformer, TR-1) = 94.15892054 390.8
% voltage drop in cable (2R-3Cx150, Al, LENGTH-65Mtrs) feeding to 160KW
= 0.35307275 1.5
motor being started
% voltage drop in 160KW motor being started = 93.80584779 389

4.0 BASIS FOR CALCULATIONS

i Fault level calculations have been done under worst condition of operation i. e. when one transformer is supplying the
complete 6.6KV & 0.415KV load.
ii In the calculations for fault level, three phase symetrical fault has been considered.
iii pu impedance of busducts has been considered zero.
iv Motor starting calculations have been done under worst condition of operation i. e. when 1no 425KW motors + 2nos 160KW
motors are running on one incomer and 2nd 425KW rated motor is started on the same incomer.
5.0 BASIS FOR SELECTION OF 6.6KV(UE) GRADE CABLES BASED ON CURRENT CARRYING CAPABILITY
i 6.6KV(UE) grade XLPE insulated cables having Aluminium conductor and conforming to IS-7098(Part-2)-1985, have been
selected to carry 100% load of 6.6/0.433KV, 1600KVA transformer.
Current drawn by 2x425KW rated motors when
= 92.0 A(approx)
loaded at 100% of their capacity
Current drawn by transformer when loaded at
= 144.0 A(approx)
100% of its capacity
Total current carried by inoming cable = 236.0 A(approx)

Current rating of 1-3C x 240sqmm AL conductor

= 390 A
XLPE insulated cable in air
0
Deration for 50 C ambient temperature = 0.87
Deration for method of laying (2no cables,
= 0.84
Horizontal, touching)

Current rating of 1-3C x 240sqmm AL conductor

= 285.01 A(approx) OK
XLPE insulated cable in air under site condtions

However, 6.6KV(UE) grade cable selected = 1-3C x 240 sqmm AL conductor XLPE insulated

ii For power supply to 425KW rated motors 6.6KV(UE) grade XLPE insulated cables having Aluminium conductor and
conforming to IS-7098(Part-2)-1985, have been selected to carry running current of motor
Current carried by cable = 46 A(approx)
Current rating of 1-3C x 150sqmm AL conductor
= 290 A
XLPE insulated cable in trays
0
Deration for 50 C ambient temperature = 0.87
Deration for cables laid on cable trays = 0.75

Current rating of 1-3C x 150sqmm AL conductor

= 189.23 A(approx) OK
XLPE insulated cable in air under site condtions

iii Fault current at 6.6KV MCC bus = 27.29 KA

iv Fault withstand time (6.6KV MOTOR BREAKER)
v For XLPE insulated cables having Aluminium conductor and conforming to IS-7098(Part-2)-1985, we have
Max conductor temperature during operation
Max conductor temp during short circuit
Minimum cross-sectional area of conductor to
withstand short circuit current, A
Where,
= 27.29 KA
= 0.25 Sec
= 90 0C
= 250 0C
= (Isc/k) x (SqRt t)
A = Area of conductor in mm2
Isc = Short circuit current in KA
t = Fault withstand time in Sec
k = Constant = 0.094

Therefore, minimum cross-sectional area for

= 145 mm2 Say, 1x150 mm2
6.6KV(UE) grade cables for motors
Therefore, 425KW motor cable selected = 1-3C x 150 sqmm AL conductor XLPE insulated

Mecgale Page No. : 5 of 6 NTPC - KhSTPP

 ANNEXURE-I
Confirmation / Clarification Sheet
Fault Level Calculations (1600KVA Transformer) - (4230-162(A) – PV E – U – 004A, Rev-00)

Sl No. NTPC Observations / Comments Confirmations / Clarifications

dated 13/06/2017
1. Fault current of 6.6kV swgr shall be 40kA. Fault Confirmed. 6.6KV SWGR shall be designed
current of 415V swgr shall be 50kA. to withstand 40KA fault current while
415V SWGR shall be designed to
withstand 50KA fault current. However,
calculations submitted are to ascertain
actual fault currents encountered by
6.6KV and 415V SWGR’s.

2. Cable sizes selected are in order. Noted. We have started the process of
procurement of HT cable(s) and shortly be
submitting technical details from sub-
vendor for your approval.

3. (Fault Clearing Time (Max) considered for cable sizing Noted. Calculations revised accordingly.
should be considered as) 0.12Sec.

4. Cable screen size shall be designed for 300A for 2 Noted and agreed. The same shall be
seconds taken care of while submitting technical
details from sub-vendor for your approval.

5. Running and starting voltage drop calculation to be Already done. Please refer S No 3.2 & 3.3
submitted separately of calculations submitted.

6. (p u impedance of utility - negligible, remove) Need not be ignored since it is

comparable to other system component
p u impedances.

7. Motor shall contribute fault current as per its locked We are not sure under what condition
rotor kVA/kW ie LR KVA/KW=6/(eff*pf) running motor can contribute fault
current to the extent of 6FLC. In our
opinion this is only one of the criteria for
deciding K value for fault contribution by
any running motor. However, since fault
contribution by running motors is very
nominal we have revised the calculations
as desired by you.

8 (Total fault load contribution by running motors) - Calculations revised.

Incorrect

9 Fault level at 6.6KV Switch Board bus at rated voltage The MVA specified by you is designed
due to utility - 6.6*1.732*40 fault withstand capability of 6.6KV SWBD
Value is incorrect while value calculated is the actual fault
coming on main busbars when the SWBD
is connected to a system through 1-3C x
240 sqmm AL conductor XLPE insulated
 ANNEXURE-I
Confirmation / Clarification Sheet
Fault Level Calculations (1600KVA Transformer) - (4230-162(A) – PV E – U – 004A, Rev-00)
cable of length 250Mtrs and having 40KA
fault current upstream of this SWBD.
Needless to say calculated fault level
should be less than designed fault level of
SWBD.

9 PMCC designed to withstand 35MVA 50KA fault level Corrected in revised document.
for 1.0Sec at 415V, 50Hz.

10 % voltage drop in 425KW motor running: Please note that actual load under
96.56703722 - ? running condition shall only be 334.6KW
as such % voltage drop available across
motor shall be much more than calculated
value. However, it shall not be out of
place to mention that restriction of
voltage drop limited to 3% of rated
voltage is only applicable for LT motors as
per technical specifications & not for HT
motors.

Sl No. NTPC Observations / Comments Mecgale Confirmations / Clarifications dt

dated 19/01/2019 29/09/2019
1 Pl. provide compliance sheet of NTPC Comments Complied with.

2 Also calculate for when 2X425kw+2X160kw running Complied with in revision 2 of calculations
then attached herewith. However, under
1. when stand by 425kw is starting for changeover, normal conditions of system only 2nos
calculate in this condition starting & running voltage 425KW and 2nos 160KW motors shall run
drop in cables as such voltage drop under running
2.when stand by 160kw is starting for changeover, condition shall remain same.
calculate in this condition starting & running voltage
drop in cables (Typ.)
3 Excel sheet of all calculations in details to be attached Complied with.
(Typ.)
4 1.Cable sizing calculations to be as per amp.rating, Confirmed compliance
starting voltage drop, running voltage drop, short
circuit fault current calculations as per contract,
relevant standards etc.(Typ.),Vendor to check, ensure
& confirm (Typ.)
5 2.Transformer,HT Swgr,LT Swgr etc fault levels to be Confirmed compliance
as per contract, relevant standards etc.(Typ.),Vendor
to check, ensure & confirm (Typ.)
6 1.Calculations shown or not shown to be as per Complied with.
Contract, Tender drawings, relevant standards
7 2. Drawing is inline with all related drawings & Confirmed
documents & matched with related to other groups
eg. Mechanical, Civil, C&I etc.
8 3. Changes made from previous revisions are Complied with.
specifically mentioned in compliance sheet.
 ANNEXURE-I
Confirmation / Clarification Sheet
Fault Level Calculations (1600KVA Transformer) - (4230-162(A) – PV E – U – 004A, Rev-00)
9 4.Fault level, sizing calculations of Swgrs, Complied with.
transformers, cables etc are as per Contract, Tender
drawings, relevant standards
10 Mention all ref. drg. nos. Complied with in revision 2 of calculations
Mention SWGRs, Transformers, Cables etc drg. nos. attached herewith.
as ref. drg. nos