Typical HT & LT Power Cable Sizing Calculation

TYPICAL HT & LT POWER CABLE SIZING CALCULATION Page: 1 of 6
2M0042-7402-BE-1007 Date: 07.06.2018
√ For Approval For Review For Information
OWNER MANGALAM CEMENT LTD, KOLKATA
EPC CONTRACTOR thyssenkrupp INDUSTRIES INDIA PVT. LTD.
PROJECT 1 X 10.85 MW WHRB AT MORAK RAJASTHAN
TYPICAL HT & LT POWER CABLE SIZING

TITLE
CALCULATION
DOCUMENT NO. 2M0042-7402-BE-1007
Rev. Date Page Prepared Checked Approved
0 07.06.2018 All AK VG/CVM SCS

2M0042-7402-BE-1007 Date: 07.06.2018
TYPICAL HT & LT POWER CABLE SIZING CALCULATION
1.1.1 Important Notes
1.1.1.1 HT cabling shall be carried out with 6.6kV (UE) grade, XLPE insulated cable with
stranded aluminium conductor, extruded FRLS-PVC sheathed.
1.1.1.2 LT 415V power cables shall be 1.1kV grade, XLPE insulated, FRLS, armoured type
cable with copper conductor below 10 sq.mm. and aluminium conductor for 10
sq.mm. & above sizes.
1.1.1.3 For HT Cables selection Fault clearing time will be as below

a) 6.6kV Cable from Convertor/Distribution Transformer to 6.6 kV Switchboard-
0.2 Sec
1.1.1.4 Starting current considered as below

a) For VFD Feeder - 2.5 times of Full load Current
b) For DOL/RDOL Feeder - 7 times of Full load Current
c) For Star-Delta Feeder - 3 times of Full load Current
1.1.2 Power Cable shall be sized based on following

Short Circuit Rating (For HT Cables Only).
1.1.2.1 Current Carrying Capacity (As mentioned in cable manufacturer catalogue).
1.1.2.2 Voltage Drop.
1.1.2.3
1.1.3 Deration shall be considered for following

Ambient air temperature (K1) = 0.9 (For 50° C)
1.1.3.1
Grouping factor (K2) = 0.71
1.1.3.2 Not required
K = Overall Derating Factor = K1 x K2 =0.9 x 0.71 = 0.64
1.1.3.3 K = 0.64
1.1.4 Maximum Permissible Voltage Drops

Permissible Running Voltage Drop = 5 %
1.1.4.1
Permissible Starting Voltage Drop = 15 %
1.1.4.2
2M0042-7402-BE-1007 Date: 07.06.2018
1.1.5 HT Cable selected considering the following formula for Short circuit condition
1.1.5.1 A = Isc x √t/ K.
Where, A = Minimum area required of cable in Sq. mm.

Isc = Short Circuit rating in Amp
t = Time duration in sec
K = Constant (K= 94 FOR AL/ 140 FOR CU)
1.1.6 Voltage drop calculated using following formula
1.1.6.1 Voltage drop at starting
Vst = √3*Ist*L*{[Rac*Cos (Øst)] + [XL*Sin (Øst)]}

---------------------------------------------------
N
Where, Rac = A.C. Resistance of Cable at 90°C (Ω/kM)

XL = Inductive Reactance of Cable at 50Hz. (Ω/kM)
Cos (Øst) = Starting Power Factor
Sin (Øst) = Sine of the angle Øst (as per Log Table)
N = Number of Runs
L = Length of Cable in KM
Ist = Starting Current in Amp
1.1.6.2 Voltage drop at running
Vdr = √3*If*L*{[Rac*Cos (ØR)] + [XL*Sin (ØR)]}

-------------------------------------------------
N
Where, Rac = A.C. Resistance of Cable at 90°C (Ω/kM)

XL = Inductive Reactance of Cable at 50Hz. (Ω/kM)
Cos (ØR) = Running Power Factor
Sin (ØR) = Sine of the angle ØR (as per Log Table)
N = Number of Runs
L = Length of Cable in KM
If = Full Load Current in Amp
2M0042-7402-BE-1007 Date: 07.06.2018
1.1.7 Typical HT Cable Sizing Calculation for Distribution Transformer Feeder
Sr. Parameter Basis / Formula Value Unit Symbol

No.
Check for Short Circuit Withstand Capacity
1 Tripping time of breaker 0.2 Sec t
2 Short circuit rating for 6.6kV 40 kA Isc
3 Type of conductor AL
4 Conductor constant 94 K
5 Min. area required for cable A = Isc x √t/ K 190.3 sq.mm.
6 Minimum cable size selected 240 sq.mm.
Load Details
1 Transformer rating** 1000 kVA P
2 System voltage 6.6 kV V
3 Full load current (HT) If = kVA/(1.732 x kV) 87.5 A If
4 Selected cable- No. of cores 3C
5 Selected cable- Cross section area AL Conductor, XLPE, Ar Cable 240 sq.mm.
6 Current carrying capacity of Reference = PolyCab Catalogue 395 A I

selected cable
7 Total derating factor 0.64 DF
8 Current carrying capacity of I x DF 252.8 A

selected cable after derating
Check For Voltage Drop During Running Condition
Allowable voltage drop (%) during
1 3 %
running
2 Length of cable** 0.07 Km L
3 No. of runs 1 No.
4 Conductor resistance Ref. = PolyCab Catalogue 0.16 Ohm/Km R
5 Reactance at 50 Hz Ref. = PolyCab Catalogue 0.085 Ohm/Km X
6 Running Cos ØR 0.8 Cos ØR
7 Running Sin ØR 0.6 Sin ØR
8 Running current Same as If 87.5 If
9 Voltage drop during running Vdr = √3*If*L*{[Rac*Cos (ØR)] + 1.9 Volts Vdr
[XL*Sin (ØR)]}/N
10 % Voltage drop during running %Vdr = {Vdr/(Vx1000)}x100 0.029 % %Vdr
Remarks %Voltage drop during running is less than allowable 3%.
Check For Voltage Drop During Starting Condition
1 Allowable voltage drop (%) during 15 %

starting
3 No. of runs 1 No.
4 Conductor resistance Reference = PolyCab Catalogue 0.16 Ohm/Km R
5 Reactance at 50 Hz Reference = PolyCab Catalogue 0.085 Ohm/Km X
6 Starting Cos Øst 0.2 Cos Øst
7 Starting Sin Øst 0.98 Sin Øst
8 Starting current Ist = 10 x If 874.8 Ist
9 Voltage drop during starting V st = √3*Ist*L*{[Rac*Cos (Øst)]
12.2 Volts Vst
+ [XL*Sin (Øst)]}/N
10 % Voltage drop during starting %Vst = {Vst/(Vx1000)}x100 1.528 % %Vst
Remarks %Voltage drop during starting is less than allowable 15%.
Suitable cable size 1R x 3C x 240 sq.mm.
Hence the selected 1R x 3C x 240 sq.mm. HT 6.6kV (UE) AL cable is adequate.
2M0042-7402-BE-1007 Date: 07.06.2018
1.1.8 Typical LV Cable Sizing Calculation for VFD Motor

No.
Load Details
1 BFP Motor rating** 55 kW P
3 Full load current If = P/(1.732 x kV x 0.9 x 0.95) 89.5 A If
5 Selected cable- No. of cores 3.5C
7 Current carrying capacity of Reference = PolyCab Catalogue 142 A I

selected cable
Current carrying capacity of
9 selected cable after derating I x DF 90.88 A

running
3 No. of runs 1 No.

9 Voltage drop during running Vdr = √3*If*L*{[Rac*Cos (ØR)] + 8.7 Volts

[XL*Sin (ØR)]}/N Vdr


starting
3 No. of runs 1 No.
8 Starting current Ist = 2.5 x If 223.7 Ist
9 Voltage drop during starting Vst = √3*Ist*L*{[Rac*Cos (Øst)] 7.4 Volts
+ [XL*Sin (Øst)]}/N Vst
Suitable cable size 1R x 3.5C x 50 sq.mm.
Hence the selected 1R x 3.5C x 50 sq.mm. LT AL XLPE cable is adequate.
2M0042-7402-BE-1007 Date: 07.06.2018
1.1.8 Typical LV Cable Sizing Calculation for DOL Feeder

No.
Load Details
1 Auxiliary cooling water pump
motor rating** 55 kW P
3 Full load current If = P/(1.732 x kV x 0.8 x 0.95) 100.7 A If
5 Selected cable- No. of cores 3C
Current carrying capacity of

7 selected cable Reference = PolyCab Catalogue 179 A I
9 Current carrying capacity of I x DF 114.56 A

selected cable after derating

running
3 No. of runs 1 No.

Vdr = √3*If*L*{[Rac*Cos (ØR)] +
9 Voltage drop during running [XL*Sin (ØR)]}/N 11.7 Volts Vdr

Allowable voltage drop (%) during
1 starting 15 %

3 No. of runs 1 No.
8 Starting current Ist = 7 x If 704.8 Ist
9 Voltage drop during starting Vst = √3*Ist*L*{[Rac*Cos (Øst)] 30.6 Volts Vst
+ [XL*Sin (Øst)]}/N
Suitable cable size 1R x 3C x 70 sq.mm.
Hence the selected 1R x 3C x 70 sq.mm. LT AL XLPE cable is adequate.
Polycab Catalogue Reference - HT XLPE Cable
Cable Sizes Resistance

Helper-1 Helper-2
(sq.mm.) (Ohm/Km)
120 Cu 120Cu 0.196

150 Cu 150Cu 0.159
185 Cu 185Cu 0.127
240 Cu 240Cu 0.0965
300 Cu 300Cu 0.0769
400 Cu 400Cu 0.0602
500 Cu 500Cu 0.0468
630 Cu 630Cu 0.0362
120 AL 120AL 0.324
150 AL 150AL 0.264
185 AL 185AL 0.21
240 AL 240AL 0.16
300 AL 300AL 0.13
400 AL 400AL 0.1
500 AL 500AL 0.0774
630 AL 630AL 0.06
Reactance
for 3C
Cable
120 6.6 1206.6 0.092
150 6.6 1506.6 0.089
185 6.6 1856.6 0.087
240 6.6 2406.6 0.085
300 6.6 3006.6 0.082
400 6.6 4006.6 0.079
120 11 12011 0.117
150 11 15011 0.114
185 11 18511 0.11
240 11 24011 0.106
300 11 30011 0.103
400 11 40011 0.099
Current for 3C,XLPE

HT Cable (In Amps)
120 6.6 Cu 1206.6Cu 335

150 6.6 Cu 1506.6Cu 380
185 6.6 Cu 1856.6Cu 430
240 6.6 Cu 2406.6Cu 500
300 6.6 Cu 3006.6Cu 570
400 6.6 Cu 4006.6Cu 650
120 6.6 AL 1206.6AL 260
150 6.6 AL 1506.6AL 295
185 6.6 AL 1856.6AL 335
240 6.6 AL 2406.6AL 395
300 6.6 AL 3006.6AL 450
400 6.6 AL 4006.6AL 520
120 11 Cu 12011Cu 335
150 11 Cu 15011Cu 380
185 11 Cu 18511Cu 430
240 11 Cu 24011Cu 500
300 11 Cu 30011Cu 570
400 11 Cu 40011Cu 650
120 11 AL 12011AL 260
150 11 AL 15011AL 295
185 11 AL 18511AL 335
240 11 AL 24011AL 395
300 11 AL 30011AL 450
400 11 AL 40011AL 520
Polycab Catalogue Reference- LT XLPE Cable
Cable Sizes Resistance

Helper-1 Helper-2
(sq.mm.) (Ohm/Km)
2.5 Cu 2.5Cu 9.48

4 Cu 4Cu 5.9
6 Cu 6Cu 3.94
10 Cu 10Cu 2.34
16 Cu 16Cu 1.47
25 Cu 25Cu 0.93
35 Cu 35Cu 0.671
50 Cu 50Cu 0.495
70 Cu 70Cu 0.343
95 Cu 95Cu 0.247
120 Cu 120Cu 0.196
150 Cu 150Cu 0.159
185 Cu 185Cu 0.127
240 Cu 240Cu 0.0965
300 Cu 300Cu 0.0769
2.5 AL 2.5AL 15.5
4 AL 4AL 9.48
6 AL 6AL 5.9
10 AL 10AL 3.94
16 AL 16AL 2.44
25 AL 25AL 1.54
35 AL 35AL 1.11
50 AL 50AL 0.82
70 AL 70AL 0.567
95 AL 95AL 0.41
120 AL 120AL 0.324
150 AL 150AL 0.264
185 AL 185AL 0.21
240 AL 240AL 0.16
300 AL 300AL 0.128
Reactance
for 3C
Cable
2.5 0.0985
4 0.0927
6 0.0884
10 0.0837
16 0.0808
25 0.0805
35 0.0783
50 0.075
70 0.074
95 0.0724
120 0.0712
150 0.0716
185 0.0718
240 0.071
300 0.0705
Current (In Amps)
3C 2.5 Cu 3C2.5Cu 30
3C 4 Cu 3C4Cu 36
3C 6 Cu 3C6Cu 47
3C 10 Cu 3C10Cu 62
3C 16 Cu 3C16Cu 79
3C 25 Cu 3C25Cu 108
3C 35 Cu 3C35Cu 132
3C 50 Cu 3C50Cu 162
3C 70 Cu 3C70Cu 198
3C 95 Cu 3C95Cu 240
3C 120 Cu 3C120Cu 276
3C 150 Cu 3C150Cu 318
3C 185 Cu 3C185Cu 366
3C 240 Cu 3C240Cu 426
3C 300 Cu 3C300Cu 480
3C 4 AL 3C4AL 31
3C 6 AL 3C6AL 50
3C 10 AL 3C10AL 67
3C 16 AL 3C16AL 70
3C 25 AL 3C25AL 96
3C 35 AL 3C35AL 117
3C 50 AL 3C50AL 142
3C 70 AL 3C70AL 179
3C 95 AL 3C95AL 221
3C 120 AL 3C120AL 257
3C 150 AL 3C150AL 292
3C 185 AL 3C185AL 337
3C 240 AL 3C240AL 399
3C 300 AL 3C300AL 455
3.5C 25 Cu 3.5C25Cu 108
3.5C 35 Cu 3.5C35Cu 132
3.5C 50 Cu 3.5C50Cu 162
3.5C 70 Cu 3.5C70Cu 198
3.5C 95 Cu 3.5C95Cu 240
3.5C 120 Cu 3.5C120Cu 276
3.5C 150 Cu 3.5C150Cu 318
3.5C 185 Cu 3.5C185Cu 366
3.5C 240 Cu 3.5C240Cu 426
3.5C 300 Cu 3.5C300Cu 480
3.5C 25 AL 3.5C25AL 96
3.5C 35 AL 3.5C35AL 117
3.5C 50 AL 3.5C50AL 142
3.5C 70 AL 3.5C70AL 179
3.5C 95 AL 3.5C95AL 221
3.5C 120 AL 3.5C120AL 257
3.5C 150 AL 3.5C150AL 292
3.5C 185 AL 3.5C185AL 337
3.5C 240 AL 3.5C240AL 399
3.5C 300 AL 3.5C300AL 455
4C 4 Cu 4C4Cu 36
4C 6 Cu 4C6Cu 47
4C 10 Cu 4C10Cu 62
4C 16 Cu 4C16Cu 79
4C 25 Cu 4C25Cu 108
4C 35 Cu 4C35Cu 132
4C 50 Cu 4C50Cu 162
4C 70 Cu 4C70Cu 198
4C 95 Cu 4C95Cu 240
4C 120 Cu 4C120Cu 276
4C 150 Cu 4C150Cu 318
4C 185 Cu 4C185Cu 366
4C 240 Cu 4C240Cu 426
4C 300 Cu 4C300Cu 480
4C 4 AL 4C4AL 31
4C 6 AL 4C6AL 50
4C 10 AL 4C10AL 67
4C 16 AL 4C16AL 70
4C 25 AL 4C25AL 96
4C 35 AL 4C35AL 117
4C 50 AL 4C50AL 142
4C 70 AL 4C70AL 179
4C 95 AL 4C95AL 221
4C 120 AL 4C120AL 257
4C 150 AL 4C150AL 292
4C 185 AL 4C185AL 337
4C 240 AL 4C240AL 399
4C 300 AL 4C300AL 455

Typical HT &amp; LT Power Cable Sizing Calculation

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TYPICAL HT & LT POWER CABLE SIZING CALCULATION Page: 1 of 6

2M0042-7402-BE-1007 Date: 07.06.2018

√ For Approval For Review For Information

OWNER MANGALAM CEMENT LTD, KOLKATA

EPC CONTRACTOR thyssenkrupp INDUSTRIES INDIA PVT. LTD.

PROJECT 1 X 10.85 MW WHRB AT MORAK RAJASTHAN