Contents

1. General

2. General Condition

3. Design Criteria

4. Cable Data’s and Cable Ampacities

5. Calculation of Cable Size for Low Voltage and Medium Voltage

CALCULATION OF CABLE SIZING

T5CE-01-E08-GA-030-C

1
 CALCULATION OF CABLE SIZING

1. General
These design citeria covers choosing the conductor size of power cables for following
system.

a. 6,3 kV power cable system

b. 0,4 kV power cable system

2. General condition

2.1 Basic deign data :

a. Frequency is 50 Hz
b. Ambient air temperature is 40 0C
c. Ambient earth temperature is 20 0C
d. Thermal reistivity (RHO) soil is 90 0C.cm/watt

2.2 Application of power cable system

6,3 kV power system : 6/10 kV Cooper conductor XLPE insullated,

Cooper tapes screen, and Outer sheathed PVC
Up to 400 V power system : 0,6/1 kV Cooper conductor XLPE insulated, and
Outer sheathed PVC

2.3 Insulation and jacket operation temperature

a. Normal Continuous Operation : 90 0C

b. Maximum Emergency Operation : 130 0C

c. Maximum Short Circuit Operation : 250 0C

3. Design Criteria

3.1 Code and Standard

a. IEC Standard
b. ICEA Standard
c. IEEE Standard
d. NFPA Standard

2
3.2 Cable seection

For choosing the conductor size of power cable, the following factor shall be
considered :

a. Minimum size of conductor based on short circuit capacity

b. Allowable continuous current rating of cable
c. Allowable voltage voltage drop cable

3.3 Minimum size of conductor

(1) The minimum size of conductor withstand a short circuit current shall be taken
into considered following factor :

a) Maximum short circuit current

b) Maximum duration time of short circuit current
c) Under worst conditions, the conductor temperature shall not exceed its
maximum short circuit teperature of 250 OC

(2) Calculation formula

Formula given by the IEC 986 (Shown on below) have been used to select the
minimum size of cable.

It = K S ( θf + ß )/ ln (θi + ß)

The above equation can be simplified as

S = I √ t / 143

Where ;
I = maximum short circuit current ( r.m.s over duration ) (A)
t = maximum duration time of short circuit current(S)
K = constant dependig on material of conductor = 226 (AS ½ / mm2)
S = cross sectional area of conductor(mm2)
Θf = final temperature of conductor = 250 (OC)
Θi = initial temperature of conductor = 90 (OC)
ß = reciprocal of temperature coefficient of resistance of conductor at
0 OC = 234,5
ln = log e

(3) The minimum of size of cable to 0,38 kV motor circuit shall be of 2,5 mm2

(4) The minimum size of cable for equipment loads from Distribution Panel Boards
( minimum 6 A MCCB) shall be of 2,5 mm2

3
3.4 Allowable continuous current rating of cable

(1) The allowable continuous current rating cable shall be determined in accordance
with standard as follows :

a. IEC 287 Calculation of continuous current rating of cables (100 % load factor)
b. IEC 364 – 5 – 523 Current Carrying Capacities

(2) Cable ampacity shall be at least 100 % of name plate rating full load current for
motor. And non motor loads cable ampacity shall be at least 100 % maximum
continuous load current.

(3) The cable is routed through several type of installation such as run via cable tray,
direct burial, underground duct, the cable ampacity shall be base on the part of
the cable run with the lowest current rating

(4) Calculation of rated currents and starting currents.

The rated current and the starting current of a motor, or a load are based in
principle, on the values which provided by the equipment manufacturers

(5) If the values not available, the basic equations below shall apply.

a. Rated currents In (A)

DC Direct Current 2 wire system ........... In = P / V

AC 1, 2W Single phase 2 wire system ........... In = P / V.Cosθ.η
AC 2, 3W Three phase 3 wire system ........... In = P / √3 V.Cosθ.η
AC 2, 4W Three phase 4 wire system ........... In = P / √3 V.Cosθ.η

Where :

In , Rated Current (A)

P , Rated Load (kW) or (kVA)
V , Rated Voltage (V)
Cosθ , Power Factor (at rated load)
η , Efficiency (at rated load)

b. Starting current; Is(A)

Is = Ks x In

Where;

Is , Starting Currents (A)

In , Rated Currents (A)
Ks , Current multiplication at starting

4
 The values for Calculations of Rated Currents and Starting Currents.

Current Power factor

Type of Load Power
No Efficiency multiple at at Starting
Factor
Starting
Medium Voltage 0,2
1 0,85 0,95 7
Motor
Low Voltage 0,3
2 0,85 0,93 6,5
motor
Small motor
0,6
3 (motor operating 0,8 0,93 4,5
valve)
N/A
4 Transformer 0,85 N/A N/A
Ac Single phase N/A
5 0,8 N/A N/A
circuit
N/A
6 DC circuit N/A N/A 4.0

c. Allowable voltage drop cable

The allowable voltage drop (%) of cable are ;

Circuit Allowable voltage drop

Normal operation Starting of motor

Motor Circuit 2,5 % 15 %

Other circuit 3% N/A

Allowable Voltage Drop (V) = Rated voltage x (%)/100

Formula for voltage drops are :

5
 1. Voltage drop value at rated load : ∆Vn(V)

DC Direct Current ∆Vn = 2 . ln . L . Rdc

2 wire system

AC1ф 2 W Single phase ∆Vn = 2 . In . L . (R Cosθ + X Sinθ)

2 wire system
AC1ф 3 W Single phase ∆Vn = In . L . (R Cosθ + X Sinθ)
3 wire system
AC3ф 3 W Three phase ∆Vn = √3 In . L . (R Cosθ + X Sinθ)
3 wire system
AC3ф 4 W Three phase ∆Vn = In . L . (R Cosθ + X Sinθ)
4 wire system

2. Voltage drop value at starting : ∆Vs(V)

DC Direct Current ∆Vs = 2 . ls . L . Rdc

2 wire system
AC1ф 2 W Single phase ∆Vs = 2 . Is . L . (R Cosψ + X Sinψ)
2 wire system
AC3ф 3 W Three phase ∆Vs = √3 Is . L . (R Cosψ + X Sinψ)
3 wire system
AC3ф 4 W Three phase ∆Vs = Is . L . (R Cosψ + X Sinψ)
4 wire system

Where:

∆Vn =
Voltage drop value at rated load (V)
∆Vs =
Voltage drop value at starting (V)
In =
Rated current (A)
Is =
Starting current (A)
L =
Length of cable
R =
Cable resistance at maximum temperatue of cable
conductor( R , AC resistance, Rdc, DC resistance)
Cosθ = Power factor at motor rated load
Cosψ = Power factor at motor starting

4. Cable Data’s and Cable Ampacities

6
Base on the above matters and manufacturers cable data’s, the values of cable
ampacities can be found as table below;

 
Cable Datas and Cable
     
Ampacities for Low Voltage

Type and IN IN Max DC

Cable
Voltage Size of GROUND AIR resistance
No Ampacities
(kV) CABLE 20 C
O
30 C
O
at 20 C
O
(Amp)
(mm²) (Amp) Amp) (Ω/km)
1 0,6/1 N2XY 4 x 2,5 41 32 7,41 22,4
2 0,6/1 N2XY 4 x4 53 41 4,61 28,7
3 0,6/1 N2XY 4 x6 67 53 3,08 37,1
4 0,6/1 N2XY 4 x 10 89 71 1,83 49,7
5 0,6/1 N2XY 4 x 16 116 96 1,15 67,2
6 0,6/1 N2XY 4 x 25 151 130 0,727 91
7 0,6/1 N2XY 4 x 35 181 159 0,524 111,3
8 0,6/1 N2XY 4 x 50 208 193 0,387 135,1
9 0,6/1 N2XY 4 x 70 254 245 0,268 171,5
10 0,6/1 N2XY 4 x 95 305 302 0,193 211,4
11 0,6/1 N2XY 4 x 120 347 349 0,153 244,3
12 0,6/1 N2XY 4 x 150 392 400 0,124 280
13 0,6/1 N2XY 4 x 185 441 464 0,0991 324,8
14 0,6/1 N2XY 4 x 240 511 552 0,0754 386,4
15 0,6/1 N2XY 4 x 300 576 677 0,0601 473,9

    Cable Datas and Cable    

Ampacities for Low Voltage
7
 Type and IN IN Max DC
Cable
Voltage Size of GROUND AIR resistance
No Ampacities
(kV) CABLE 20 OC 30 OC at 20 OC
(Amp)
(mm²) (Amp) Amp) (Ω/km)
1 0,6/1 N2XY 3 x 2,5 41 32 7,41 22,4
2 0,6/1 N2XY 3 x 4 53 41 4,61 28,7
3 0,6/1 N2XY 3 x 6 65 52 3,08 36,4
4 0,6/1 N2XY 3 x 10 89 71 1,83 49,7
5 0,6/1 N2XY 3 x 16 117 96 1,15 67,2
6 0,6/1 N2XY 3 x 25 153 130 0,727 91
7 0,6/1 N2XY 3 x 35 184 159 0,524 111,3
8 0,6/1 N2XY 3 x 50 217 193 0,387 135,1
9 0,6/1 N2XY 3 x 70 269 245 0,268 171,5
10 0,6/1 N2XY 3 x 95 323 302 0,193 211,4
11 0,6/1 N2XY 3 x 120 367 349 0,153 244,3
12 0,6/1 N2XY 3 x 150 412 400 0,124 280
13 0,6/1 N2XY 3 x 185 470 464 0,0991 324,8
14 0,6/1 N2XY 3 x 240 546 552 0,0754 386,4
15 0,6/1 N2XY 3 x 300 632 677 0,0601 473,9

Cable Datas and Cable Ampacities

for Medium Voltage
     
8
 IN
IN Max DC
Type and Size GROU Cable
Voltage AIR resistance
No of CABLE ND 20 Ampacities
(kV) O 30 C
O
at 20 C
O
(mm²) C (Amp)
Amp) (Ω/km)
(Amp)
1 6 kV/10 kV N2XSY 1 x 25 157 162 0,708 105,3
2 6 kV/10 kV N2XSY 1 x 35 187 195 0,514 126,75
3 6 kV/10 kV N2XSY 1 x 50 220 234 0,379 152,1
4 6 kV/10 kV N2XSY 1 x 70 269 292 0,262 189,8
5 6 kV/10 kV N2XSY 1 x 95 321 354 0,189 230,1
6 6 kV/10 kV N2XSY 1 x 120 364 407 0,150 264,55
7 6 kV/10 kV N2XSY 1 x 150 405 460 0,122 299
8 6 kV/10 kV N2XSY 1 x 185 457 527 0,097 342,55
9 6 kV/10 kV N2XSY 1 x 240 528 621 0,074 403,65
10 6 kV/10 kV N2XSY 1 x 300 593 729 0,059 473,85
11 6 kV/10 kV N2XSY 1 x 400 665 815 0,046 529,75

Cable Datas and Cable Ampacities

for Medium Voltage
     
IN
IN Max DC
Type and Size GROU Cable
Voltage AIR resistance
No of CABLE ND 20 Ampacities
(kV) 30 OC at 20 OC
(mm²) O
C (Amp)
Amp) (Ω/km)
(Amp)
1 6 kV/10 kV N2XSEBY 3 x 25 145 141 0,727 91,65
2 6 kV/10 kV N2XSEBY 3 x 35 173 168 0,524 109,2
3 6 kV/10 kV N2XSEBY 3 x 50 205 201 0,387 130,65
4 6 kV/10 kV N2XSEBY 3 x 70 248 250 0,268 162,5
5 6 kV/10 kV N2XSEBY 3 x 95 293 299 0,193 194,35
6 6 kV/10 kV N2XSEBY 3 x 120 330 340 0,153 221
7 6 kV/10 kV N2XSEBY 3 x 150 367 385 0,124 250,25
8 6 kV/10 kV N2XSEBY 3 x 185 409 434 0,099 282,1
9 6 kV/10 kV N2XSEBY 3 x 240 459 496 0,0754 322,4
10 6 kV/10 kV N2XSEBY 3 x 300 503 548 0,0601 356,2
11 6 kV/10 kV N2XSEBY 3 x 400 552 607 0,047 394,55

5. Calculation of Cable Size for Low Voltage and Medium Voltage

5. 1 Calculation of Cable Size for Low Voltage (0,6/1 kV)

9
CALCULATION OF CABLE SIZE (N2XY,N2XBY, 0,6/1 kV) FOR MOTORS
BASE ON CABLE AMPACITY

10
 Cap Current Justify for
Core Cable Safety
Motor of Ampacities Ratio Safety
No size size Factor
3ф Motor of Cable( Ia) Im/Ia Factor
(sq.mm) (sq.mm) (%)
(kW) (Im) (25%)
1 4 6,80 22,4 0,30 4 x 2,5 0,30 70 ok
2 5,5 9,35 28,7 0,33 4x4 0,33 67 ok
3 7,5 12,75 37,1 0,34 4x6 0,34 66 ok
4 11 18,70 37,1 0,50 4x6 0,50 50 ok
5 15 25,50 49,7 0,51 4 x 10 0,51 49 ok
6 18,5 31,45 49,7 0,63 4 x 10 0,63 37 ok
7 22 37,40 67,2 0,56 4 x 16 0,56 44 ok
8 25 42,50 91 0,47 4 x 25 0,47 53 ok
9 30 51,00 91 0,56 4 x 25 0,56 44 ok
10 37,5 63,75 111,3 0,57 4 x 35 0,57 43 ok
11 45 76,50 111,3 0,69 4 x 35 0,69 31 ok
12 55 93,51 135,1 0,69 4 x 50 0,69 31 ok
13 75 127,51 171,5 0,74 4 x 70 0,74 26 ok
14 95 161,51 244,3 0,66 3 x 120 0,66 34 ok
15 110 187,01 292 0,64 3 x 150 0,64 36 ok
16 132 224,41 324,8 0,69 3 x185 0,69 31 ok
17 160 272,02 386,4 0,70 3 x240 0,70 30 ok
18 200 340,02 509,54 0,67 2x3x120 0,67 33 ok
19 250 425,03 649,6 0,65 2X3x185 0,65 35 ok
20 315 535,53 772,8 0,69 2X3X240 0,69 31 ok

CALCULATION OF CABLE SIZE (N2XY,N2XBY, 0,6/1 kV) FOR MOTORS

BASE ON CABLE AMPACITY

Cap Current
Core Cable Safety Justify for
Motor of Rated of Ratio
No size size Factor Safety Factor
3ф Motor Cable( Ic) Im/Ia
(sq.mm) (sq.mm) (%) (25%)
(kW) (Im)
1 4 6,80 32 0,21 4 x 2,5 0,21 79 ok
11
 2 5,5 9,35 41 0,23 4x4 0,23 77 ok
3 7,5 12,75 53 0,24 4x6 0,24 76 ok
4 11 18,70 53 0,35 4x6 0,35 65 ok
5 15 25,50 71 0,36 4 x 10 0,36 64 ok
6 18,5 31,45 71 0,44 4 x 10 0,44 56 ok
7 22 37,40 96 0,39 4 x 16 0,39 61 ok
8 25 42,50 130 0,33 4 x 25 0,33 67 ok
9 30 51,00 130 0,39 4 x 25 0,39 61 ok
10 37,5 63,75 159 0,40 4 x 35 0,40 60 ok
11 45 76,50 159 0,48 4 x 35 0,48 52 ok
12 55 93,51 193 0,48 4 x 50 0,48 52 ok
13 75 127,51 245 0,52 4 x 70 0,52 48 ok
14 95 161,51 349 0,46 3 x 120 0,46 54 ok
15 110 187,01 400 0,47 3 x 150 0,47 53 ok
16 132 224,41 464 0,48 3 x185 0,48 52 ok
17 160 272,02 552 0,49 3 x240 0,49 51 ok
18 200 340,02 698 0,49 2x3x120 0,49 51 ok
19 250 425,03 928 0,46 2X3x185 0,46 54 ok
20 315 535,53 1104 0,49 2X3X240 0,49 51 ok

5. 2 Calculation of Cable Size for Medium Voltage (6/10 kV)

CALCULATION OF CABLE SIZE (N2XSY,N2XSEBY, 6/10 kV) FOR MOTORS

BASE ON AMPACITY AND RATED CURRENT OF CABLE

12
 Rated Justify
Rated
Ampacities Curren Ratio Safet for
Current of Core size Cable size
No of Cable t of Current y Safety
Feeder/Mot (sq.mm) (sq.mm)
( Ia) Cable (Ifm/Ia) Factor Factor
or (Ifm)
(Ia) (25%)
1 16,80 91,25 0,18 N2XSEBY 3 x 25 141,00 0,12 88,09 ok
2 28,80 91,25 0,32 N2XSEBY 3 x 25 141,00 0,20 79,57 ok
3 38,40 91,25 0,42 N2XSEBY 3 x 25 141,00 0,27 72,77 ok
4 39,20 91,25 0,43 N2XSEBY 3 x 25 141,00 0,28 72,20 ok
5 40,00 91,25 0,44 N2XSEBY 3 x 25 141,00 0,28 71,63 ok
6 42,40 91,25 0,46 N2XSEBY 3 x 25 141,00 0,30 69,93 ok
7 57,60 91,25 0,63 N2XSEBY 3 x 25 141,00 0,41 59,15 ok
8 57,60 113,75 0,51 N2XSEBY 3 x 25 175,00 0,33 67,09 ok
9 121,60 130,65 0,93 N2XSEBY 3 x 25 201,00 0,60 39,50 ok
10 137,60 130,65 1,05 N2XSEBY 3 x 25 201,00 0,68 31,54 ok
11 183,20 264 0,69 N2XSY 3 x 1 x 120 407 0,45 54,99 ok
12 200,80 194,35 1,03 N2XSEBY 3 x 95 299,00 0,67 32,84 ok
13 211,20 194,35 1,09 N2XSEBY 3 x 95 299,00 0,71 29,36 ok
14 229,60 264 0,87 N2XSY 3 x 1 x 120 407 0,56 43,59 ok
15 275,20 267,8 1,03 N2XSY 3 x 1 x 120 412 0,67 33,20 ok
16 275,20 261,3 1,05 N2XSEBY 2 x 3 x 50 402 0,68 31,54 ok
17 275,20 327,6 0,84 N2XSEBY 3 x 3 x 35 504 0,55 45,40 ok
18 324,00 299 1,08 N2XSY 3 x 1 x 150 460 0,70 29,57 ok
19 344,00 299 1,15 N2XSY 3 x 1 x 150 460 0,75 25,22 ok
20 630,00 299 2,11 N2XSY 3 x 2 x 1 x 150 460,00 0,65 35,00 ok
21 613,60 299 2,05 N2XSY 3 x 2 x 1 x 150 460,00 0,67 33,30 ok
22 630,40 342,55 1,84 N2XSY 3 x 2 x 1 x 185 527 0,60 40,19 ok
23 739,20 342,55 2,16 N2XSY 3 x 2 x 1 x 185 527 0,70 29,87 ok
24 872,00 403 2,16 N2XSY 3 X 2 x 1 X240 621,00 0,70 29,79 ok
25 1250,00 403 3,10 N2XSY 3 X 2 x 1 X240 621,00 0,67 32,90 ok
26 1132,80 403 2,81 N2XSY 3 X 2 x 1 X240 621 0,61 39,19 ok
27 1176,00 403 2,92 N2XSY 3 X 2 x 1 X240 621,00 0,63 36,88 ok
28 1600,00 473,85 3,38 N2XSY 3 x 3 x 1 x 300 729 0,73 26,84 ok
29 1516,80 473,85 3,20 N2XSY 3 x 3 x 1 x 300 729 0,69 30,64 ok
30 2243,20 473,85 4,73 N2XSY 3 x 5 x 1 x 300 729 0,62 38,46 ok
31 3150,00 473,85 6,65 N2XSY 3 x 7 x 1 x 300 729 0,62 38,27 ok
32 3670,40 473,85 7,75 N2XSY 3 x 8 x 1 x 300 729 0,63 37,06 ok

Note, Cable No, 8,15,16, and 17 are 12/20 kV

13
14