POWER CABLE DESIGN, CONSTRUCTION,

TESTING

BY H.K. RAMANATH, B.E (ELEC)

RETD EXECUTIVE ENGR,
KARNATAKAPOWER CORPORATION LTD,
BANGALORE.

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POWER CABLE DESIGN, CONSTRUCTION, TESTING

1.0 INTRODUCTION:

Before of the introduction of Power cables power supply is to be extended from source to
any equipment through an Over head conductors made of Copper or Aluminium
Conductors. Later came and are used to extend the power supply from source to an
equipment such as Transformers, Motors, Distribution Panels etc. Initially power cables
were used for Medium & Low voltage application. However due to improving in the
manufacturing Technology and in particular insulation of cables, Power cables are
extensively used in EHV Transmission lines.

The following are the advantages in using Power Cables against Overhead conductor.
1) Greater freedom from interruption of service such as from Thunder storm,
Severe weather Conditions, Short Circuits Earth Faults due to Flashovers,
breaking of Conductors, Insulators, Objects falling across the lines etc.
2) Less liability of accidents to public.
3) Avoidance ugly appearance of overhead lines.
However the cost of installation of Power Cable is higher than Over Head Lines.

2.0 CABLE DESIGN:

Cable design vary enormously to meet the diverse application. But there are certain
components which are common to all types of cables.
a) Low resistance conductor to carry the normal current & also short circuit currents.
b) Insulation cover to isolate the conductor from each other & surroundings.
c) Screening to obtain a radial electrostatic field.
d) A metal sheath to keep out moister.
e) Armouring for mechanical strength

3.0. VOLTAGE DESIGNATION:

According to nominal system voltages, the power cable are grouped as under.
a) Low voltage cable 660 volts / 1100 volts.
b) Medium / High Voltage cables 3.3 KV/ 6.6 KV / 11 KV.
c) EHV Cables 33 KV/66KV/110KV/220KV & 400 KV Cables.

4.0 TYPES OF POWER CABLES:

There are two main types of power cables with reference to its construction & Insulation.
a) PVC Insulated Cables

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b) XLPE Cable.

3 core PVC Insulated 3 1/2 core PVC insulated 4 core PVC insulated
Un armoured armoured un armoured

Carbon structure of PVC cables

H H H H H
I I I I I
-- C--C--C-- C--C
I I I I I
H H H H H

b) Cross linked polyethylene insulated power cable (XLPE cable)

Carbon structure of XLPE cables

H H H
I I I I
-- C-- C --C -- C
H H I H
H H I H
-- C-- C --C -- C
I -- H -- I -- H

5.0 CABLE SIZING CALCULATIONS:

5.1 LV Power cables sizing is carried out in order to meet the continuous load current and
short circuit conditions.
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5.2 Eg for a motor feeder of rated 0.55 KW.
Considering 1 run of 4 core x 2.5 Sq mm XLPE, copper cable is used to feed to 415 v load
rated 0.55 KW.
a) Running Voltage drop Calculation:-
Motor actual rated KW
Running Current (I) required to = --------------------------------- Amps.
fed power to motor √ x 0.415 x 0.85 x 0.9

0.55
= ---------------------------- = 1 amp.
√3 x 0.415 x 0.85 x 0.9

A.C Resistance (R) at 90 0 C = 9.48 Ohm/Kms ----------from the table of Cable Manufacturer.
Reactance (X) at 50 Hz = 0.0985 Ohm/ Kms ----------- from the table of Cable Manufacturer.
Load power Factor (Cos Ø) = 0.85.(during Motor running condition).
Load power Factor (Cos Ø) = 0.30.(during starting of Motor.).

(R Cos Ø + X Sin Ø)
Voltage Drop = √ 3 x I x ----------------------------- x L Volts
(N x 1000)

( 9.48 x 0.85 + 0.985 x 0.53)

Voltage Drop = 1.732 x 1 x --------------------------------------- x L Volts
(1 x 1000)
= 0.014 x L Volts.

Maximum allowable Voltage drop during running condition = 3 % of rated voltage i.e. 415
V +/- 3 % = 427.5 or 402.5 volts.
So the maximum distance that can be laid 3 x 415
for this KW rating at 415 Volts is = ------------------------- = 889.28 mtrs.
100 x 0.014

b) Starting Voltage drop Calculation:-

(R Cos Ø + X Sin Ø)
Voltage Drop = √ 3 x I x ----------------------------- x L Volts
(N x 1000)

( 9.48 x 0.30 + 0.985 x 0.53)

Voltage Drop = 1.732 x 6 x --------------------------------------- x L Volts
(1 x 1000)
= 0.0305 x L Volts.

Maximum allowable Voltage drop during running condition = % of rated voltage i.e. 415 V
+/- 10 % = 456.5 or 373.5 volts.

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So the maximum distance that can be laid

10 x 415
for this KW rating at 415 Volts is = ------------------------- = 1360 mtrs.
100 x 0.0305
c) Calculation for De rated current:-
Current de rating of a given size of XLPE cable per run in free air at ambient temp at 40
deg C from Manufacturer's data sheet, two stage de rating factor is applied.
i) Temperature De rating Factor:
Temperature de rating factor (Kt)for 50 deg C ambient temp = 0.89 (as per XLPE
insulated LT Power Cable Catalogue.
ii) Group de rating Factor:
Group De rating factor (Kg) is taken as = 0.68 (Empirical Value).
Overall de rating factor K = Kt x Kg = 0.89 x 0.68 = 0.6.

KW HRC LET MIN CABLE MAX ENERGY A

RATING FUSE THROUGH SIZE CABLE CAN
(UP TO) RATING ENERGY OF ACCORING WITHSTAND SC
HRC FUSE (IN TO FUSE (IN K AMP2 -SEC
K AMP2 -SEC RATING 9IN
SQ mm)
0.55 4 0.01 6 0.318
1.1 6 0.0169 6 0.318
1.5 10 0.0576 6 0.318
2.2 16 0.09 6 0.318
3.7 20 0.1521 6 0.318
5.5 25 0.1764 6 0.318
7.5 32 0.2025 6 0.318
11 50 0.2809 6 0.318
18.5 63 0.8464 10 0.884
22 80 1.02 16 2.262
30 100 1.44 16 2.262
45 125 1.96 16 2.262
55 160 3.0625 25 5.523
75 200 3.61 25 5.523
110 250 5.76 35 10.824
132 315 7.84 35 10.824
160 400 11.9 50 22.09
De rated Current I is derived as = Ir x K, where Ir = Rated current for the cable used to
feed power to the load. The selection criteria shall be that the de rated current will be
always more than the running current of the system. Continuous Current rating for
standard condition of laid in air at 40 deg C is 30 Amps.
Overall de rating factor is 0.6.
So de Rated current of 1 x 2.5 sq mm copper cable = 30 X 0.6 = 0.18 amps.
As such cable used is in order.
d) Calculation for short Circuit withstand Capacity:- TYPICAL VALUES OF
MINIMUM CABLE SIZE SELECTED FOR DIFFERENT KW RATING

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 Here the fuse provides protection against short circuit. Hence the energy experienced by
the cable during short circuit condition must be more than the 'Let Through ' energy
allowed by fuse before it melts on a short circuit fault.
The short circuit Current Rating of 4c 2.5 sq mm cable is 0.36Ka for 1 sec.
So the derived value of max energy the cable can withstand under SC fault = 0.36 x 0.36 =
0.1296 KA2 - sec.
For 0.55 KW motor HRC fuse rating as per table is 4 amps & let through energy is 0.01
KA2 - sec. Hence 1 4C 2.5 sq mm for a distance of 889 mtrs, cable used is in order.

5.3 Cable sizing Calculation - HT cable (1 1 & 3.3 KV System).

Determination of minimum allowable size of cable based on short circuit Current

withstand ability Calculation.
TABLE - 1

FUSE RATING MINIMUM PRE MAX TOTAL I2 t

IN AMPS ARCING I2 t Amp2sec
2
Amp sec
630 338 x 10 4 1880 x 10 4
4
500 216 x 10 1240 x 10 4
400 96 x 10 4 640 x 10 4
4
350 84.5 x 10 450 x 10 4
315 54.1 x 10 4 310 x 10 4
250 24.1 x 10 4 160 x 10 4
4
200 13.6 x 10 99 x 10 4
160 6.01 x 10 4 50 x 10 4
4
125 3.39 x 10 31.5 x 10 4
100 1.72 x 10 4 19.5 x 10 4
4
80 0.97 x 10 11.0 x 10 4
60 0.43 x 10 4 4.9 x 10 4
50 0.28 x 10 4 3.2 x 10 4
Energy that can withstand by a given size of XLPE insulated Cable is derived as under.
TABLE - 2

Area of Cable Short circuit fault Derived value of

Cross section withstand energy that the
(mm 2) capacity of the cable can
cable for 1 sec withstand during
a short Ckt (A 2)
50 4.7 2209 x 10 4
70 6.6 4329.6 x 10 4
95 8.93 7974.5 x 10 4
120 11.28 12723.8 x 10 4
150 14.1 19881 x 10 4
185 17.5 30241.2 x 10 4
240 22.6 50895.4 x 10 4
300 28.2 79524 x 10 4

The selection of for HT cable is that the max value of 'Let Through' energy of HT fuse during

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short ckt, as mentioned in Table - 1 & 2 has to be less than the energy that the cable can
withstand during a short ckt fault. By comparing the respective values mentioned in Table 1 7
2 it can be said that 50 mm 2 XLPE HT Cable is suitable for use in Vacuum contactor feeders
backed up by an HT fuse rated equal or less than 630 amps.

5.4 VOLTAGE DROP CALCULATION:

Voltage drop in a cable during running or starting condition of a motor is derived by the
following formula.

(R Cos Ø + X Sin Ø)
Voltage Drop (dv) = √ 3 x I x ----------------------------- x L Volts
(N x 1000)
Where ,
dv= Voltage drop in cable (in Volts).

I = Current flowing in the cable (in amps).

N = Number of runs of cable being used.
R = AC resistance of the cable per run at 90 deg C (in Ω/Km).
X = Reactance of the cable per run at 50 Hz (in Ω/Km).
L = Length of the cable ( in meters).
Cos Ø = Load Power Factor (during running condition , load power factor is assumed to be =
0.85 and during motor starting condition , load power factor to be = 0.3.
Now percentage voltage drop during running or starting condition can be derived as
dV
% Voltage drop = ------- x 100
V
Where dV is voltage drop during running condition = ≤ 3 %
Where dV is voltage drop during starting condition = ≤ 10 %
V= Rated system voltage

5.5 CURRENT DE RATING USING DERATING FACTORS:

Current de rating of a given size of XLPE cable per run in free air at ambient temp at 40
deg C from Manufacturer's data sheet, two stage de rating factor is applied.
i) Temperature De rating Factor:
Temperature de rating factor (Kt)for 50 deg C ambient temp = 0.89 (as per XLPE
insulated LT Power Cable Catalogue.
ii) Group de rating Factor:
Group De rating factor (Kg) is taken as = 0.68 (Empirical Value).
Overall de rating factor K = Kt x Kg = 0.89 x 0.68 = 0.6. De rated Current I is
derived as = Ir x K, where Ir = Rated current for the cable used to feed power to the
load. The selection criteria shall be that the de rated current will be always more than
the running current of the system.

5.6 TYPICAL HT CABLE SIZING CALCULATION:

FOR HT LOADS FED BY VACUUM CKT BREAKER (VCB)
According to minimum cross section of cable required for 40 KA short ckt fault is 170.2
sq mm for VCB feeders.
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 Considering 3 c x 240 sq mm HT XLPE Cable to supply power to 3.3 KV motor.
required length of cable as per layout diagram = 1355 mtrs.

Rating of the motor = 750 KW.

750
Running Current (I) = ---------------------------- Amps.
√ 3 3.3 x 0.85 x 0.9

= 171.5 Amps.
A.C Resistance (R) at 90 deg C = 0.16 Ω/Kms.
Reactance (X) at 50 Hz = 0.0737 Ω/Kms.
No of runs of Cable being used.= 1
Load P.f (Cos Ø) = 0.85 during running , Sin Ø= 0.53
Load P.f (Cos Ø) = 0.3 during starting.

(0.16x 0.85 + 0.0737 x 0.53)

Voltage Drop (dv) = √ 3 x 171.5 x --------------------------------------- x 1355
during running (1 x 1000)
= 70.5 Volts.

70.5
% Voltage drop = --------- x 100 = 2.1 % i.e ≤ 3 % Hence OK.
during running 3300

Motor starting Current = 6 x 171.5 Amps = 1029 Amps.

(0.16x 0.3 + 0.0737 x 0.95)

Voltage Drop (dv) = √ 3 x 1029 x --------------------------------------- x 1355
during starting (1 x 1000)
= 285 Volts.

285
% Voltage drop = --------- x 100 = 8.6 % i.e ≤ 10 % Hence OK.
during starting 3300

5.7 TESTS ON CABLES:

The following tests are conducted on power cables as per IS 1554 Part 1.
a) Acceptance tests
i) Conductor Resistance Test
ii) Annealing Test [For Copper]
iii) Tensile Strength Test [For Aluminium]
iv) Wrapping Test [For Aluminium]
v) Thickness of Insulation & Sheath.
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 vi) Tensile Strength & Elongation Test of Insulation & Sheath.
vii) Oxygen & vii) Temperature Index Test [For FRLS PVC / FRHF Insulation & Sheath.]
viii Smoke Density Test
ix) HCL Gas Generation Test
x) Insulation Resistance Test.
xi) High Voltage Test at Room temperature.
xii) Flammability Test.

b) Routine Tests - The following shall constitute routine tests:

1) Conductor resistance test,
2) High voltage test at room temperature, and
3) Armour resistance test ( for mining cables ).

c) Type Tests:-
i) Conductor Resistance Test
ii) Annealing Test [For Copper]
iii) Tensile strength Test [For Aluminium]
iv) Wrapping Test [For Aluminium]
v) Thickness of Insulation & Sheath.
vi) Tensile Strength & Elongation Test of Insulation & Sheath.
vii) Ageing in air Oven of Insulation & Sheath.
viii) Shrinkage Test of Insulation & Sheath.
ix) Hot Deformation Test of Insulation & Outer Sheath.
x) Heat Shock Test of Insulation & Outer Sheath.
xi) Loss of Mass Test of Insulation & Outer Sheath.
xii) Oxygen & Temperature Index Test
xii) Smoke Density Test
xiv) HCL Gas Generation Test
xv) Insulation Resistance Test.
xvi) High Voltage Test [water Immersion & at Room temperature]
xvii) Flammability Test.
d) Optional Tests - The constitute optional tests: following shall
1) Cold bend test,
2) Cold impact test, and
3) Armour resistance test ( for other than mining cables ).
4) Additional Ageing Test.

e) High Voltage Test at Room Temperature -

The cable shall withstand an a.c. voltage of 3 kV ( rms ) or a dc voltage of 7’2 kV. The
duration of test shall be 5 minutes for each connection.
f) High Voltage Test ( Water Immersion Test )
A.C . Test - The core or cores ( not exceeding five cores in the case of multi core cables )
shall be carefully removed from a sample approximately 3 m long taken from the finished
cable. They shall be SO immersed in water bath that their ends protrude at least 200 mm
above the water level. The temperature of the water bath shall be 6O +/- 3 deg C for cores
with general purpose PVC insulation and 70-& deg C for cores with heat resisting PVC
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 insulation. After 24 hours, a voltage of 3 kV ( rms ) shall be applied between the
conductors and water. This voltage shall be raised to 6 kV ( rms ) within 10 seconds
and held constant at this value for 5 minutes. If the sample fails in this test, one more
sample shall be subjected to this test. There shall be no failure in the repeat test.
g) D.C. Test - The cores which have passed the preliminary test in 16.3.1 shall be
subsequently tested with a D.C. voltage of 1’2 kV in the same water bath at the same
temperature. The core shall withstand this voltage for 240 hours without breakdown.
h) Flammability Test - Period of burning after removal of the flame shall not exceed 60
seconds and the unaffected ( un charred ) portion from the lower edge of the top clamp
shall be at least 50 mm.

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