TYPICAL CALCULATIONS

FAULT LEVEL CALCULATION

1. Faul level at 11 KV Bus: -

Actual fault level at 11KV Bus = 500 MVA

(Source fault level at SRGEL Bus)
500
Fault current = ---------- = 26.2 KA
√3 x 11

Max. Fault current = 26.2 x 1.1 = 28.8 KA

(Due to variation in system voltage)

Let the base KVA = 1000 KVA

100 x 1
% Impedance of the system at source = --------- = 0.2%
500
II. Fault level at SRIL:-

Let the base KVA = 1000 KVA.

Impedance of Cable connecting 11KV

Outgoing feeder upto 11KV O/H line. = 40 mts (approx.)

Similarly, O/H line from SRGEL Plant

To SRIL Plant route length = 200 mts (approx.)

Assuming cable size = 11 KV 3C x 300 sq.mm AR. Al. XLPE cable

O/H line conductor = DOG ACSR Conductor.

Conductor resistance = 0.129 x 0.04 = 0.00516 Ω

Conductor reactance = 0.0999 x 0.04 = 0.004 Ω

Impedance Z of the Cable = √ (0.00516) 2 + (0.004) 2

Total impedance = 0.00652 Ω

ohmic value x KVA (base)

% Impedance of the cable = --------------------------------
10 x (KV)2

0.00652 x 1000
= ------------------ = 0.0054%

1
 10 x 11 x 11
ACSR Resistance = 0.27450 x 0.2 = 0.0549Ω

ACSR Reactance = 0.580 x 0.2 = 0.116Ω

ACSR Impedance Z = √ (0.0549) 2 + (0.116) 2

= 0.128Ω

Ohmic value x KVA (base)

% Impedance of the cable = --------------------------------
10 x (KV) 2

0.128 x 1000
= ------------------ = 0.1057%
10 x 11 x 11
Total impedance up to Plant Terminal Point: -

% Impedance of the systems = 0.2 %

% Impedance of the cable = 0.0054 %
% Impedance of the ACSR conductor = 0.1057%
0.3111 %

100
Fault Level = ---------- = 321.44 MVA
0.3111

321.44
Fault current = ---------- = 16.87 KA
√3 x 11

Max. Fault current = 16.87 x 1.1 = 18.55 KA.

Fault Level at 433V Bus:

Capacity of the Transformer = 1750 KVA.

Impedance of the Transformer of 1750 KVA = 6%

6
Impedance of the transformer at 1000 KVA base= ------- x 1000 = 3.428 %
1750
Total Impedance at 433 Bus:

% Impedance of the system = 0.3111%

% Impedance of the Transformer = 3.428%
----------
3.739%
----------
100
Fault Level = ----- = 26.745 MVA.

2
 3.739

26.745
Fault current at Transformer LT side = --------- = 35.66
KA
√3 x 0.433

Max. fault current due to variation in system voltage =35.66 x 1.1 =

39.22KA

Connecting LT side Terminals of Transformer and Main PCC through LT Busduct.

Assuming Size of Bus bars / phase =2 x 200 x 12 mm / phase.

Enclosure size and material = 850 x 500 mm Al.

Length of the Bus duct = 8 mtrs.

Type of Bus bar material = Al. Grade D50SWP.

DC Resistance = 12.14 / 2 = 6.07 M.Ω /

mtr at 20˚C
At 85˚C RDo = 6.07 x 1.236

= 7.502 M.Ω / mtr.

Reactance of single Bus bar = 96.78 / 2 = 48.39 M.Ω / mtr.

7.502 x 8
AC resistance for 8 M long busduct = -----------
S1000

= 0.060 Ω.

Reactance = (0.5 x 8) / 1000 = 0.004 Ω

Bus bar Impedance = √ (0.060)2 + (0.004)2

= 0.0601 Ω.

0.0601 x 1000
% Impedance of the busduct = -----------------
10 x (0.433)2

= 32.073

Fault level at PCC level:

% Impedance upto Transformer LT side = 3.739

3
% Impedance of Busduct = 32.073
--------
35.812%

100
Fault level at PCC side = -------- = 2.792 MVA.
35.812

Since connecting the busduct the fault level becomes very low. Hence we have
not considered for the calculation purpose.

Hence assuming the fault level at PCC Bus level

is same as the fault level of Transformer LV side = 26.744 MVA.
S
26.744
Fault current at PCC Panel = --------- = 35.66 KA
√3 x 0.433

Hence Switch gear in PCC and Bus bars are rated for 50 KA for 1 Sec.

11 KV Cable Size Selection:

11KV Cable between the 11KV VCB Panel in the SRGEL Plant to upto 11KV
O/H Cable Termination Kit.
1750 KVA
Full load current capacity for Transformer = -------------- = 114.8 A
√3 x 11x 0.8

De-rating factor for cable due to Temperature = 0.95

Current carrying capacity of cable = 114.8 / 0.95 = 120.86 A.

Allowing over loading of cable 10% = 120.86 x 1.1 = 132.94 A

3C x 300 sq.mm Ar. Al. XLPE Cable in Ground

can carry a Max. current of : 340 A.

Hence the size selected is adequate.

Checking Fault Level withstand Capacity:

Fault level current (IK) = 26.2 KA.

Short circuit duration = 1 Sec.

Min. size of cable required to withstand the 26.2 x √1

Short circuit current = ----------- = 278
sq.mm
0.094

4
 However, the selected size of the cable is 300 sq.mm Ar. Al. XLPE Cable.

Hence, the selected size of the HT cable is ok.

Maximum Earth Fault Current in 433V System:

% Supply system Impedance including cable contribution

and O.H line and Transformer at 1000KVA base. = 3.739%.

%Z x 10 x (KV)2
Ohmic value of the Impedance of the supply system = ---------------------
KVA (Base)

3.739 x 10 x (0.433)2
= --------------------------
1000

= 0.007010 Ω

Positive phase sequence Impedance of the system = 0 + j 0.007010Ω

Negative phase sequence Impedance of the system = 0 + j 0.007010Ω

Zero phase sequence Impedance of the system = 0 + j 0.007010Ω

Impedance of the earthing system = 3 + j 0.0

--------------------
Total Impedance = 3 + j 0.021030

3 x 433
Earth fault current = 3E / ZE = --------------------
√3 x (3 + j 0.021030)

√3 x 433
= ------------ = 249.97 A.
3.0000756

= 0.25 KA.

Max. Earth fault current (due to variation in system voltage) = 0.25 x S1.1 = 0.275 KA.

Selection of Neutral Bus:

Symmetrical short circuit current = 39.22 KA.

Duration of fault current = 5 Seconds (assumed)

The Earth bus size required for brazed joint = 0.0044 x If x √5

5
 = 0.0044 x 39220 x √5 sq. mm.

= 365.8 sq. mm Cu.

Hence the Neutral Bus used 75 x 6 (or) 50 x 8 Cu. (2400 sq. mm Cu).

Calculation for Bus bar Selection (3000 A):

1. Bus bar chosen : 2 nos. 200 x 12 Al. Bus bar / phase.

: 1 no. 200 x 12 Al. Bus bar for Neutral.

2. Installation : Indoor / Outdoor well ventilated.

3. Enclosure material and size : MS 850 x 450 sq.mm.

4. Phase spacing (distance between bus bars) : 100mm

5. Configuration of Bus bars : W-V-U-U-V-W-N.

6. Design Ambient Temperature : 40˚C

7. Max. allowable Temperature Bus bar over Ambient : 45˚C

8. Bus bar configuration : Interlaced side by side.

9. Open air rating of Bus bars 2 nos-200x12 Al. mm Flat : 3060 x 2 = 6120 A

Correction Factors:

1. Temperature correction factor

(Design Amb. 50˚C and Temp. rise 35˚C) : 0.942

Spacing between conductor

2. Proximity effect = --------------------------------- : 100 / 12 = 8.3 =1
Width of conductor

7 x 200 x 12
3. Enclosure correction factor : --------------- x 100 = 4.392 = 0.8
850 x 450

4. Enclosure material factor for MS. : 0.8

5. Up rating factor for painting of Bus bars : 1.2

6. For ventilation enclosure provided with

Louvers at all sides : 1.0

Combined correction factor = 0.881 x 1 x 0.75 x 0.8 x 1.2 x 1.0

(Multiple of above factors)
= 0.63432

6
7. Current carrying capacity after de-rating = 6120 x 0.63432 = 3882 A.

8. Rating required = 3000 A.

Hence, the Bus bar size and size of enclosure are adequate and size of bus bars should
be not less than 4500 sq. mm.

Min. size require for the Bus bars size checking:

Fault level of the Transformer = 50 KA at 415V.

Short Circuit Current ISC = 14x104x (A/√t)(√(log10)((Tm+258)/(T0+258)))

WhereIsc = 50 KA (or) 50,000 A.
A = Area of Aluminium Bus bar in sq. inch.
T = Duration of Short Circuit ( 1 Sec.)
TM = Final Bus bar Temp. after short circuit 200˚C
T0 = Initial Bus bar Temp. Before short circuit 85˚C

50,000 = 14x104x (A/√1)(√(log10)((200+258)/(85+258)))

A = (50,000/(14x104)x(1/{√(log-
10((200+258)/(85+258)}

= 1.0078 sq. inch

= 650 sq. mm

Hence Min. size of Bus bar required in LT side to

Withstand 50KA fault Current for 1 Sec. = 650 sq. mm

SELECTION OF SWITCH GEAR RATINGS:

1. Main PCC Panel:

1.1 Transformer Incomer:

1. Transformer Capacity = 1750 KVA.

1750
2. LV side full load current = ------- = 2334 A.
1.732 x 0.433

3. Allowing 10 % Over load = 2334 x 1.1 = 2566.8 A.

= 2600 A (Say).
Hence selected 3200 A, 50 KA TPN ACB is adequate.

1.2 Emergency Incomer-2:

7
 During the fault (or) during maintenance of Main Transformer feeder, the
Emergency feeder can be operated for running emergency loads (or) running the
maintenance loads.

Total Max. Emergency loads connected = 543.79KW = 544 KW (say).

Max. Demand/Load factor of Emergency Loads = 0.65

Max. Demand of emergency load = 353.6 KW.

353.6
Full load current = ------------------------ = 578 A
1.732 x 0.415 x 0.85

Allowing fluctuation 10% = 578 x 1.1 = 635.8 A.

Hence selected 630A SFU with 630A HRC Fuse for the Emergency Feeder is
adequate.

1.3 DG Incomer:

For plant maintenance purpose during shut down period.

DG capacity = 160 KVA.

160
Full load current = ---------------- = 222.5 A.
1.732 x 0.415

Allowing over loading 10% = 222.5 x 1.1 = 244.75 A.

Hence selected MCCB rating 250A TPN is adequate.

2. OUT GOING FEEDERS

2.1. Raw Material Process Plant feeder:

For Phase 1 & 2 total Max. Demand = 290 KW
290
Full load current = -----------------
1.732 x 0.415 x 0.8

Full load current = 504.3 A

Allowing over loading 10% = 504.3 x 1.1 = 554.73 A

Say = 600 A.

8
 Hence selected 1000 A TPN 415V, 50Hz, 50 KA ACB.

2.2 DRP-1 Feeder:

For phase-1 max demand = 500 KW

500
Full load current = -----------------------
1.732 x 0.415x 0.8

= 869.5 A

Allowing 10% over loading = 869.5 x 1.1

= 956.45 A

Hence the selected one step higher size ACB rating = 1250A

2.3. Waste Heat Recovery Plant-1 Feeder:-

For phase-1 max. demand = 200 KW

200
Full load current = ----------------------
1.732 x 0.415x 0.8

= 347.8 A.

Consider 10% over loading = 347.8 x 1.1

= 382.5 A.

Hence selected 630 A SFU and rating of HRC fuse is 400A.

2.4 ESP-1 & 2 Feeder:

For phase-1 & 2 total max. Demand = 120 KW

120
Full load current = ---------------------- =
208.68A
1.732 x 0.415x 0.8

Allowing 10% over loading = 208.68 x 1.1 = 229.5A.

Say = 230 A.

Hence selected SFU Unit rating 250A with 250 A HRC fuse rating is adequate.

9
 2.5 For Power & Lighting Loads:

a. Lighting loads Max. = 45 KW.

(Including Plant Lighting and Outdoor Lighting)

b. Welding and other miscellaneous loads = 50 KW.

c. A/C loads and other auxiliary loads = 80 KW.

------------
Total loads = 175 KW

Utility factor & demand factor = 0.8 x 0.9

Max. Demand = 175 x 0.8 x 0.9

=126 KW =130 KW(Say).

Allowing future expansion 10% = 130 x 1.1 = 143 KW.

143
Max. Full load current = --------------- = 248 A.

1.732 x 0.415 x 0.8

Hence selected SFU switch rating 630 A and fuse rating 350 / 400 A HRC Fuse.

2.6 UPS / Instrumentation Feeder:

UPS, Emergency lighting, Data and Instrumentation loads = 40 KW.

40
Max. Full load current = ---------- = 69.5A
√3 x o.415 x 0.8

Additional future loads 10% = 76.5 A.

Hence selected SFU rating 125 A is adequate.

General:
To measure the Power Digital Load Manager are provided for all the incomer
feeders in addition Ammeter, Voltmeter, Power Factor Meter, etc.

CABLE SIZING:

1. From PCC to DRP-1:

Total load current including overloading, etc = 956.45A = 957A (say)

Selected cable size = 3.5C x 300 sq. mm Ar. Al. PVC Cable.

10
 AC current rating in air = 315 A (as per IS: 1554).

De-rating Factor:

Ambient air temperature in Trench = 0.9

Cable touching in Trench = 0.9

Applying De-rating factor = 315 x 0.9 x 0.9 = 255A.

Total no. of runs required = 957 / 255 = 3.75.

Hence min. 4 runs of 3.5C x 300 sq. mm Ar. Al. PVC Cable to be laid.

Short Circuit Rating Check:

3.5C x 300 sq. mm can withstand 22.73 KA for 1 Second.

No. of runs 4 x 22.73 = 90.92 KA.

Hence the size and runs are adequate.

2. From PCC to RMP-1:

Total load current including overloading, etc = 670 A

Selected cable size = 3.5C x 300 sq. mm Ar. Al. PVC Cable.

AC current rating in air = 315 A (as per IS: 1554).

De-rating Factor:

Ambient air temperature in Trench = 0.9

Cable touching in Trench = 0.9

Applying De-rating factor = 315 x 0.9 x 0.9 = 255A.

Total no. of runs required = 670 / 255 = 2.62

i.e, Min. 3 runs of 3.5C x 300 sq. mm Ar. Al. PVC Cable to be laid.

However, the rating of ACB is 1000A on in either sides.

Hence selected 4 runs of 3.5C x 300 sq. mm Ar. Al. PVC Cable considering the
switch gear rating. Regarding Short Circuit rating – 4 runs 3.5C x 300 sq. mm Ar. Al.
can withstand 90.92 KA for 1 Second.

3. From PCC to WHRB-1 & 2:

11
 Total load current including overloading, etc = 382.5 A

Selected cable size = 3.5C x 300 sq. mm Ar. Al. PVC Cable.

After De-rating = 255 A.

Total no. of runs required

= 382.5 / 255 = 1.5

Select 2 runs of 3.5C x 300 sq. mm Ar. Al. PVC Cable which can withstand fault
current of 45.46 KA for 1 Second.

4. From PCC to ESP:

Total full load current including overloading, etc = 230 A

Selected cable size = 3.5C x 300 sq. mm Ar. Al. PVC Cable.

After De-rating = 255 A.

Total no. of runs required = 230 / 255 = 0.9

One run of 3.5C x 300 sq. mm Ar. Al. PVC Cable is adequate.

Cable Sizing For Outgoing Feeders:

Basis:

a. Starters for upto 15KW Motors are DOL Starters.

Above 15 KW Motors are Star/Delta Starters.

b. For easy procurements and standarding the cable size, the following cable size are
selected.

After
De-rating
S. No. Cable Size In Air de-rating
Factor
(A) (A)

1 3C x 6 sq. mm Ar. Al. PVC Cable. 30 0.7 21

2 3C x 10 sq. mm Ar. Al. PVC Cable. 40 0.7 28

3 3C x 16 sq. mm Ar. Al. PVC Cable. 51 0.7 36

4 3C x 25 sq. mm Ar. Al. PVC Cable. 70 0.7 49

5 3C x 50 sq. mm Ar. Al. PVC Cable. 105 0.7 73

12
 6 3C x 70 sq. mm Ar. Al. PVC Cable. 130 0.7 91
3C x 240 sq. mm Ar. Al. PVC
7 280 0.7 196
Cable.
3C x 2.5 sq. mm Ar. Cu. PVC
8 24 0.7 17
Cable.
Note:
Due to reliability of the system, we have not considered 3C x 2.5 sq. mm and 3C x 4
sq. mm Al. Cable which may easily break during laying and termination in the small
motor ends, also non-availability of space in the terminals.

1.1 For Raw Material Process Plant Loads (cabling between PMP-1 to various
loads):

1. For 15 KW Motors:

1. Approximate route length = 210 mtrs.

2. Type of Starting = DOL

15
3. Full load current = --------------------------
√3 x 0.415 x 0.83 x 0.92

= 27.32 A = 28 A (say).

4. Size of cable selected = 3C x 25 sq. mm.

5. Current carrying capacity in air = 70

6. Applying de-rating factor due to Ambient & touching = 0.7

7. After de-rating = 70 x 0.7 = 49 A

Voltage Drop Check:

1.44
For 3C x 25 sq. mm Cable voltage drop = --------- V/A/mtrs.
1000

1.44
Applying the same = --------- x 28 x 210.
1000

= 8.467 V.

During starting condition = 8.46 x 6 = 50 V.

8.46

13
 Percentage voltage drop under normal running condition = ------- x 100

230

= 3.6%.

Which is acceptable limit of 5% voltage drop.

Hence selected size is adequate for 15KW motor.

The following motors are in this category.

1. BC-1 Gr. Hopper to coal Screen House.
2. Ground Hopper to screen House BC-6.

2. For 11 KW Motors:

1. Approximate route length = 210 mtrs.

11
2. Full load current = --------------------------
√3 x 0.415 x 0.83 x 0.92

= 20.04 A

3. Size of cable selected = 3C x 16 sq. mm.

4. Current carrying capacity of the cable after de-rating = 36 A.

Voltage Drop Check:

2.29
For 3C x 16 sq. mm Cable voltage drop = --------- V/A/mtrs.
1000

S2.29
Applying the same =--------- x 20 x 210 = 9.618V.
1000
9.618
Percentage voltage drop under normal condition = ------- x 100 = 4.18%.
230

This is less than acceptable limit of 5% voltage drop.

Hence selected size is adequate for 11KW motor.

The following motors are in this category.

1. From Crusher & Screen to Day Bin BC-8.
2. BC-3 Crusher House to Screen On Day Bin..
3. I/O Crusher-1.
4. I/O Crusher-2.
5. Vibro Screen Coal Sec.

14
 6. BC-7 from Crusher House to Tr. House (9.3 KW).

3. For 7.5 KW Motor:

1. Approximate route length = 210 mtrs.

2. Full load current = 14 A.

3. Size of cable selected = 3C x 10 sq. mm.

4. Current carrying capacity of the cable after de-rating = 28 A.

Voltage Drop Check:

3.60
For 3C x 10 sq. mm Cable voltage drop = ------ V/A/mtrs.
1000

3.60
Applying the same = ------ x 14 x 210 = 10.584V.
1000

10.584
Percentage voltage drop under normal condition = ------- x 100 = 4.6%.
230

Which is less than acceptable limit of 5% voltage drop.

Hence selected size is adequate for the following 7.5KW motors.

1. BC-2 Gr. Hopper to coal Screen House.
2. Vibrating Screen for Coal (primary).
3. Vibrating screen for I.O.
4. From I Bin to CD Conv. BC-14.
5. V Screen PH.
The same size cable 3C x 10 sq. mm is suitable and adequate for 5.5KW Motors
of following Motor feeders: -
1. From Screen House to yard (Fines).
2. BC-4 from BC-3 to Top of Screen.
3. BC-5 from G.H to Day Bin Top.

4. For 2.2 KW Motor:

1. Approximate route length = 210 mtrs.

2. Full load current = 5 A.

3. Size of cable selected = 3C x 6 sq. mm.

4. Current carrying capacity of the cable after de-rating = 21 A.

Voltage Drop Check:

15
 6.02
For 3C x 6 sq. mm Cable voltage drop = ------ V/A/mtrs.
1000

6.02
Applying the same = ------ x 5 x 210 = 6.321V.
1000

6.321
Percentage voltage drop under normal condition = ------- x 100 = 2.74%.
230

Which is less than acceptable limit of 5% voltage drop.

Hence selected size is adequate for the following motors.

1. Mag Sep to Sil Bin Reversible Conve. On PSB BC-16.
2. Conv. On PSB Mag Sep to Char Bin BC-17.
3. Vibro Feeder at Mag / Sep.
4. Mag Concentrator / Sep.
5. Mag Concentrator / Sep.
6. Mag Concentrator / Sep.
7. Mag Concentrator / Sep.
8. Mag Concentrator / Sep.

5. For Smaller Rating Motors below 0.75 KW:

1. Approximate route length = 210 mtrs.

2. Full load current = 1.8 A.

3. Size of cable selected = 3C x 2.5 sq. mm Cu.

4. Current carrying capacity of the cable after de-rating = 17 A.

Voltage Drop Check:

Voltage drop = 4.67 V.

4.67
Percentage voltage drop = ------- x 100 = 2.033%.
230

Which is less than acceptable limit of 5% voltage drop.

Hence the selected size of sCable is applicable for the following motor feeders.

For all Vibro Feeders and Star Feeders.

6. For 55 KW Motor (Coal Crusher):

16
 1. Approximate route length = 210 mtrs.

2. Type of Starter = Star / Delta.

3. Full load current (P.C) = 57.5 A.

4. Size of cable selected = 3C x 50 sq. mm.

5. Current carrying capacity of the cable after de-rating = 73 A.

Voltage Drop Check:

0.77
For 3C x 50 sq. mm Cable voltage drop = ------ V/A/mtrs.
1000

0.77
Applying the same = ------ x 57.5 x 210 = 9.29 V.
1000

9.27
Percentage voltage drop under normal condition S= ------- x 100 = 4.0425%.
230
Which is just sufficient. Better to have next size cable.

7. For 22 KW Motor:

1. Approximate route length = 210 mtrs.

2. Type of Starter = Star / Delta.

3. Full load current (P.C) = 23 A.

4. Size of cable selected = 3C x 16 sq. mm.

5. Current carrying capacity of the cable after de-rating = 36 A.

Voltage Drop Check:

2.29
For 3C x 16 sq. mm Cable voltage drop = ------ V/A/mtrs.
1000

2.29
Applying the same = ------ x 23 x 210 = 11.06 V.
1000

11.06
Percentage voltage drop under normal condition = ------- x 100 = 4.809%.
230
Which is just sufficient. Better to have next size cable.

The same size cable is adequate for 18.5KW Motors also.

17
 Following Motors are applicable
a. Bay Filter-1
b. Bay Filter-2
c. Bay Filter-3
d. Bay Filter-4

8. Coal Crusher Feeder – 55 KW – Direct Feeding:

Main Cable between RMP Panel Feeder to Local Starter Feeder.

55
Max. Full load current = ---------- = 99.13A
√3 x o.415 x 0.83 x 0.93

Additional future loads 10% = 99.13 x 1.1 = 109 A.

3.5C x 120 sq. mm Ar. Al. Cable can carry in Air = 180 A

Applying De-rating factor = 0.7

After applying de-rating factor = 180 x 0.7 = 126 A.

Voltage Drop Check:

Approximate route length = 210 mtrs.

0.31
Voltage drop = ------ V/A/mtrs.
1000

0.31
Applying the same = ------ x 109 x 210 =7.0959 V.
1000

7.096
Percentage voltage drop under normal condition S=
------- x 100 = 3.08%.
230
Hence the cable size between 55KW Feeder from RMP Feeder Local Starter
3.5C x 120 sq. mm Ar. Al. cable is adequate.

1.2 FOR DRP LOADS:

Cabling Between DRP-1 to Various Loads:

I. For 15KW Motors:

1. Inverter:

18
 The cable selected = 3C x 25 sq. mm Ar. Al. PVC Cable (which is already
been explained in the earlier pages).

II. For 11KW Motors:

The cable selected = 3C x 16 sq. mm Ar. Al. PVC Cable (which is already
been explained in the earlier pages) and following feeders are applicable.

1. Kiln Shell Air fan Inv. Panel.

2. Hot Well Pump 1 & 2.
3. Cooling Tower Fan.

III. For 7.5KW Motors:

The cable selected = 3C x 10 sq. mm Ar. Al. PVC Cable (which is already
been explained in the earlier pages) and following feeders are applicable.

1. Kiln Nose Cooling Fan.

2. Nose Cooling Fan.
3. Sealing Air Fan.
4. Cooler Inlet Nose Cooling Fan.
5. ABC Fan 1 & 2.
IV. For 5.5KW Motors:

The cable selected = 3C x 10 sq. mm Ar. Al. PVC Cable (which is already
been explained in the earlier pages) and following feeders are applicable.

1. Day Bin to KCTB.

2. Tr. House to ABC BC-11.
3. Day Bin to Tr. House BC-10.
4. CD Conveyor BC-13.

V. For 3.7 KW Motors:

1. Approximate route length = 100 mtrs.

2. Full load current (P.C) = 7.4 A.

3. Size of cable selected = 3C x 6 sq. mm Al.

4. Current carrying capacity of the cable after de-rating = 21 A.

Voltage Drop Check:

6.02
For 3C x 6 sq. mm Cable voltage drop = ------ V/A/mtrs.
1000

S6.02
Applying the same = ------ x 7.5 x 100 = 4.515 V.
1000

19
 4.515
Percentage voltage drop under normal condition = ------- x 100 = 1.96%.
230
Voltage drop is less than 5%. Hence cable size is adequate which is applicable
for the following Motor Feeders.
i. Coal Injector.
ii. Kiln Aux. Drive.
iii. Wet Sraper.
iv. Cooler Aux. Drive.
v. Dewatering Pump 1, 2 & 3.
vi. Volem Feeder.
vii. Kiln Transition Chute (2.2 KW).
viii. Kiln Thruster (2.2 KW).
ix. Cooler Thrust device (2.2 KW).
x. Power Pack (2.2 KW).

For smaller rating Motors below 1.5KW Motor can be used 3C x 2.5 sq. mm Cu. Cable.
The details already explained in the earlier working.
For,
1. WF1 to WF-5, (* 4C x 2.5).
2. Volem Feeder, (* 4C x 2.5).
3. Kiln inlet PV and outlet PV.
4. Kiln Lub Pump.
5. Cooler Thrust Brake.
6. Cooler Lubricant Panel.
7. Cooler Dish D.P.V.
8. ID Fan Damper.
9. L.D.O Pump 1 & 2.

Note: * indicates 4C x 2.5 sq. mm Cu. Cable & others are 3C x 2.5 sq. mm Cu. Cable.

Following Feeders from DRP-1 to various feeders Local Starter Panels cable
sizing.

S. No. From To Load Size of Cable R.L (M)

1 DRP-1 MCC Inverter Lobe 55KW 1x3.5C-120 sq. mm 85

Compressor Panel

2 DRP-1 MCC Kiln Shell Air Fan 77KW 1x3.5C-120 sq. mm 60

Inverter Panel

3 DRP-1 MCC Kiln Main Drive 75KW 1x3.5C-120 sq. mm 30

Inverter Panel

4 DRP-1 MCC Cooler Main Drive 22KW 1x3.5C-50 sq. mm 30

5 DRP-1 MCC Rapper Panel - 1x3.5C-120 sq. mm -

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 6 DRP-1 MCC Air Compressor Panel 55KW 1x3.5C-120 sq. mm 40

1.3 Waste Heat Recovery Boiler Plant:

1. For 75 KW Motors:

1. Approximate route length = 140 mtrs.

2. Type of Starting = Star / Delta

3. Full load current during running (P.C) = 78 A.

4. Size of cable selected = 3C x 70 sq. mm Ar. Al. Cable.

5. Current carrying capacity in air = 130

6. After de-rating = 91 A
Voltage Drop Check:
0.54
For 3C x 25 sq. mm Cable voltage drop = --------- V/A/mtrs.
1000

0.54
Applying the same = --------- x 78 x 140.
1000

= 5.89 V.

5.89
Percentage voltage drop under normal running condition = -------x 100 =2.5%.
S230

Which is less than acceptable limit.

Hence selected 2R x 3C x 70 sq. mm Ar. Al. Cable is adequate.

The following motors are in this category.

1. FD Fan.
2. For 55 KW Motor Feed Pump 1 & 2 2r x 3C x 50 sq. mm is adequate.
3. For 7.5 KW Motor Condensator Booster 1R x 3C x 10 sq. mm is
adequate.
Pump 1 & 2
4. For 0.37 KW Motor LP dosing Pumps 1 & 2 1R x 3C x 2.5 sq. mm Ar. Cu.
Cable Is adequate.
HP dosing pumps 1 & 2
HP Deposit Tank Strainer
LP Dosing Tank Strainer & Actuators.
Rotary Air Lock Valve 1&2
Feeder for Control Panel.

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1.4 ESP PANEL:

2 KW Heater Loads:

4C x 6 sq. mm Ar. Al. Cable is applicable for Hopper Heaters 1 & 2.

For Below 1 KW Feeders:

3C / 4C x 2.5 sq. mm Cu. Cable is applicable for the following:

a. Collector Rapper 1 & 2.
b. Discharge Electrode Rapper 1 & 2.
c. G.D Screw Rapper.
d. Insulator Heater 1 to 6.
e. Rotary Air Lock 1 & 2.

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Capacitor Selection:

Assuming Capacitors are connected to Main PCC Panel:

Total load for phase-1 (max. demand) = 763 KW

Total load max. demand for phase-1 & 2 = 1316 KW.

Assuming Plant power factor (max. of Induction Loads) = 0.83

Power factor to be improved up to 0.95.

Capacitor requirement for phase-1 = 763[tan(Cos –1 0.83-

tan(Cos-1 0.95) ]

Capacitor requirement = 261.9 KVAR

Total load for combined phase-1 & 2 = 1316 KW

–1
Capacitor requirement for combined Phase-1&2 = 1316[tan(Cos 0.83-tan(Cos-1 0.95) ]

Capacitor requirement = 451.8 KVAR

For Initial Phase-1 condition = 261.9 KVAR (or) 300

KVAR.

For total completion of project = 451.8 KVAR (or) 500 KVAR.

Hence proposed have initial = 300 KVAR capacitor in six steps.

i.e, 50 KVAR x 6

Latter to added another 200 KVAR in four steps = i.e, 50 KVAR x 4.

300 KVAR Capacitor current rating = 300 x 2.6 A = 780 A.

500 KVAR Capacitor current rating = 500 x 2.6 A = 1300 A.

Hence, 2 set of Capacitor Banks of rating 300 KVAR & 200 KVAR respectively in steps
of 50 KVAR and max. Switch fuse rating required for 300 KVAR is 800 A and fuse rating
also 800 A and no. of runs cable between the Capacitor Panel to PCC – 4 runs x 3.5C x
300 sq. mm Cable and capacitor panel can be provided with Power Factor controller
relay to maintain the Power Factor at particular Power Factor.

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