CABLE SIZING CALCULATION FOR 2500kVA COMMON TRANSFORMER INCOMING CABLE

CONSIDERATIONS:

1. Line to Line Voltage = 4320 Volts

2. Frequency = 60 Hz
3. Max. Allowable Voltage Drop % of Line to Line Voltage
Starting = 15% (As per tender specification:
Running = 5% CEM/ISGEC/700558-60- SECTION -II
4. Cable Overall Derating Factor D 0.7 -Design basis-serial no.19)
5. Length of the cable, L = 100 m (Assumed)

Transformer Parameters:

Transformer Rating = 1600 kVA

Transformer Efficiency at Full Load = 0.97
Hence, Transformer FLC Im = kVA/(1.732*kV*Efficiency) = 228.93 A

Cable Sizing Based on Ampacity:

Cable equivalent current at 45 degree C, Ic = I/D 327.05 A

2
Cable Size Selected = 185 mm CU, XLPE INSULATED, ARMOURED CABLE
Cable Rated Current in Air, Ca = 453 A (As per KEI catalogue)
Cable Resistance at 90 deg. C (ohm/km) , R = 0.127 (As per KEI Catalogue)
Cable Reactance (ohm/km) at 60 Hz , X = 0.10056 (As per KEI Catalogue)
No.of parallel cables required Ic/Ca 1

Cable Sizing Based on Shortcircuit withstanding capacity:

A sample calculation has been done below for minimum cable size required for a motor feeder for the specified
short circuit rating. As per IEC 60364-5-54, Clause No.543.1.1,
S = (Isc x √t) / K
Where, S: Cross sectional area, in Square milimeters
Isc: Value (a.c. rms) of fault current for a fault of negligible impedance, which can flow through the protective device in amperes.
t: operating time of the disconnecting device, in seconds.
K: factor depend on the material of the protective conductor.

Transformer Rating = 1600 kVA

Full Load Current = 228.93 A
4320V Symmentrical SC current Isc = 40000 A
Operating time t = 0.16 S
Required Cross sectional Area S 111.89 Sqmm
K - Factor Copper Aluminium
XLPE Cables 143 94
PVC Cables 115 76
Cable Voltage Drop:

Transformer Running Voltage Drop (%) = L *Sqrt(3) * IFL( R cosφr+X sin φr)
(VL-L/100)* 1000 *No.of runs
= 0.12 %

Where, L:Length of the cable in metres

IFL: Full load current in Amps.
IST: Starting current in Amps.

The % of Voltage drop is within the limit.

Hence, the Selected Cable Size is 3.6/6 (7.2)kV, 1RX3Cx185 sq.mm, (2XFY) XLPE, Flat Armoured,Copper cable
SYSTEM PARAMETERS
Nominal System Voltage kV 11
System Configuration - Ring Main
Connected Load MVA 9.35
Demand Load
Power Factor (pf)
MW
p.u 0.85
5
MV CABLE SIZING
Demand Ring Load Current (I) Amp 309
Ring Length (L) km 1.575
Maximum Permissible %Voltage Drop % 3.5

DERATING FACTORS
Method of Cable Installation The cable shall be buried directly underground at an average depth of 1000 ~ 1100mm in trefoil configuration.
Ground Temperature Correction Factor 0.83 Assuming a ground temperature of 500 C
Depth of Laying Correction Factor 0.96 Assuming a burial depth of 1100 m
Soil Thermal Resistivity Correction Factor 0.77 Assuming dry soil with thermal resistivity of 2.0 K.m/W
Cable Grouping Correction Factor 1.0 Only applicable to multiple circuits
Harmonic Current Correction Factor 1.0 Assuming a third harmonic content of less than 15%
Total Cable Current Derating Factor 0.61

CABLE SIZING
Cable Voltage Grade 8.7/15 kV
Cable Construction 1 x 3 Core Cu/XLPE/SWA/XLPE 3 x 1 Core Cu/XLPE/AWA/PVC 3 x 1 Core Al/XLPE/AWA/PVC
2
Cable Size (S) mm 185 240 300 185 240 300 300 400 500
Cable Resistance (R ) ohm/km 0.128 0.098 0.079 0.127 0.098 0.078 0.13 0.102 0.08
Cable Reactance (X) ohm/km 0.1 0.09 0.09 0.12 0.11 0.11 0.11 0.11 0.1
Rated Current Carrying Capacity Amp 383 436 481 405 463 516 405 454 507
Derated Current Carrying Capacity Amp 235 268 295 248 284 317 248 279 311
Voltage Drop Volt 136 110 96 144 119 105 142 122 102
%Voltage Drop % 1.24 1.00 0.88 1.31 1.08 0.95 1.29 1.11 0.92
Short Circuit Current Rating for 1 sec kAmp 45 47
Short Circuit Current Rating for 3 sec kAmp 25 28

SELECTED CABLES
300 mm2 3 x 1 Core Cu/XLPE/AWA/PVC
500mm2 3 x 1 Core Al/XLPE/AWA/PVC

The two selected cables (highlighed in green) satisfy the requsite current carrying and volatge drops demands of the envisaged system and also provide short circuit current
capability equal to or beyond the 25 kA rating of 11kV feeder switchgear.
 MEDUIM VOLTAGE CABLE SIZING

1- Assumptions:
1.1 Minimum cable size for Meduim Voltage feeders is 50 sq.mm
1.2 Circuit breaker tripping time on short circuit is 200ms.
1.3 Constant reflecting conductor material constant and temperature rise during
short circuit condition is 143 for XLPE.
1.4 As per client requirement, cable sizes above 185 sq.mm shall be single
core installed in trefoil.
1.5 Starting current for medium voltage motors are equals to 5 times the full load current.

2- References:
2.1 Electrical design basis specification no.. 24613-200-3DR-E12F-00001.
2.2 PIRELLI Cables catalogue for 300V-33000V cables

3- Calculations
3.1 Medium Voltage Cable size based on short circuit current check:
Table below reflects the designed cable sizes for diffirent effective short
circuit current values.

Ieffective Cable C.S.A (mm2) CB opening XLPE

(KA) calculated designed time (sec) CONST
10 31.27 3x50 0.2 143
16 50.04 3x70 0.2 143
20 62.55 3x70 0.2 143
25 78.18 3x95 0.2 143
31.5 98.51 3x120 0.2 143
40 125.09 3x150 0.2 143
50 156.37 3x185 0.2 143
65 203.28 3(1x240) 0.2 143
80 250.19 3(1x300) 0.2 143

3.2 Medium Voltage cable size based on current carrying capacity check:
Table below reflects the designed cable sizes based on the maximum
premissible current through the MV cable after consideration of de-rating factor.

cable size Ic in air De-rating Imax

(sq.mm) (Amps) Factor (Amps)
3 x 50 220 0.683 150.26
3 x 70 270 0.683 184.41
3 x 95 330 0.683 225.39
3 x 120 375 0.683 256.125
3 x 150 430 0.683 293.69
3 x 185 490 0.683 334.67
3(1 x 240) 650 0.683 443.95
3(1 x 300) 740 0.683 505.42
3.3 Medium Voltage power feeder cable size based on voltage drop check:
a) Table below reflects the designed cable sizes based on the maximum
premissible voltage drop for the medium voltage power feeders.

cable size R X Voltage Power FLC Cable lengthVoltage

(sq.mm) (uohm/m) (uohm/m) (kVolts) Factor (Amps)(meter) Drop
3 x 50 494 107 3.3 0.8 0.00
3 x 70 343 101 3.3 0.8 0.00
3 x 95 248 95.3 3.3 0.8 0.00
3 x 120 196 92.2 3.3 0.8 0.00
3 x 150 159 89.9 3.3 0.8 0.00
3 x 185 128 87.3 3.3 0.8 0.00
3(1 x 240) 98 105 3.3 0.8 790 150 0.88
3(1 x 300) 80 103 3.3 0.8 0.00

b) Table below reflects the designed cable sizes based on the maximum
premissible voltage drop for the medium voltage motor feeders.

cable size R X PF PF FLC Cable length

Ist VoltageV. Drop V. Drop
(sq.mm) (uohm/m) (uohm/m) Running Starting (Amps) (meter) (%Ifl) (kVolts) Running Starting
3 x 50 494 107 0.8 0.3 5 3.3 0.00 0.000
3 x 70 343 101 0.8 0.3 136 500 5 3.3 1.20 3.556
3 x 95 248 95.3 0.8 0.3 5 3.3 0.00 0.000
3 x 120 196 92.2 0.8 0.3 500 1000 5 3.3 5.57 19.256
3 x 150 159 89.9 0.8 0.3 5 3.3 0.00 0.000
3 x 185 128 87.3 0.8 0.3 5 3.3 0.00 0.000
3(1 x 240) 98 105 0.8 0.3 790 100 5 3.3 0.59 2.686
3(1 x 300) 80 103 0.8 0.3 5 3.3 0.00 0.000
CABLE
SELECTON

ETEC

Written by: R. HARDIE Pr Eng

Technical Marketing Manager

'

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 How to Select an Electric Cable
AuLhor’s name; R. Hardie
Page 2 of 26

to

I Power - This can be in k\/A, kW or in Amps.

I Voltage

I Permissible voltage drop - (Usually 5%)

I Distance to load

I Fault current:

- Short circuit (Symmetrical Fault Current)

- Earth fault (Asymmetrical Fault_,,,Current)

1l'--as-i --'1~'i~-’-=""‘~h"l"€*’"~f

I Mechanical Conditions:

- Temperature, depth of burial, soil thermal resistivity

presence of other cables, or other heat sources.

-= Armouring requirements. Q=1»;»-5w"='--/ ca ~c<'°ls -4» 5)

- Sheath requirements.

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 How to Select an Electric Cable
Author s name: R. Hardie
Page 3 of 26

Whether we are given KW, k\/A or Horsepower, we need to

convert this to the required tull load current. (I)

, - - 1<W><1@@@ -
X/3x Voltage x Cos ®

Q1‘ I 3 P P
KVA
;_;.___..
x W1000
.__a.<—~— ~

(/3 X Voltage
Horsepower X 0.746 X 1000
or I --~ ~
0 J3 XVo1tage Xcose

Where :I 2 Full load current

V = Phase to phase voltage
at/5 $1.73
Cos ® : Power factor (assume Cos ® = 0.8) W i'~*'*~=‘-’

For motor starting current use: 3 x I for Star-Delta (soft start)

6 x I for Direct on line starting

Select a cable based on the required maximum current.

Now check to see whether the volt drop is acceptable.

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 Hovt to Select an Electnc Cable
Author s name R. Hardie
Page 4 of 26

B: PERMISSIBLE VOLT DROP

Look up the mV/A/m figure - The relevant table has been

reproduced later from our
Facts and Figures booklet.
5?, cw Bc:>~s>&;.{_.~._§j

Volt drop = mV/A/m x Current (Amps) x Distance (metres).

= mVolts (Convert to volts by dividing by 1000).

Usually 5% volt drop is allowed. For a 400 Volt 3 phase

system, 5% is equal to 20 Volts.

Remember that SANS 10142/1 allows a maxium voltage drop

of 5% of normal voltage. Two comments are necessary:

1. For a 380 volt system, 5% volt drop would be 19 volts

For a 400 volt system, 5% would be 20 volts
For a 420 volt system, 5% would be 21 volts — -
But you cannot assume a 40 volt drop is acceptable
when the load is 380V and the supply is 420 volts

2. The voltage drop would include all voltage drops

between the transformer and the final load. In township
reticulation normally 1 3% is used between the
transformer and the pavement kiosk, the remaining 2%
is used from the kiosk to the house.
If the voltage drop is already 5% at the main DB, then
there is nothing left to run a cable from there to a sub
DB.
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 How to Select an Electric Cable
Author s name: R. Hardie
Page 5 of 26

EXAMPLE:

Selection of low voltage cable.

100kW motor at 400 volts, cable to be installed under
standard conditions in air, over 50 metres, using a star delta
starter.

I = 100 x1000 Cos<I> = 0.9

~/3 X 400 X 0.9
= 160 Amps Full load
current.

Refer to the following table for cable selection: "ct

Vt’
_ (_.__(__._(_k'L c_.~<§.;€<»_
Select a 50mm2 cable and note mV/A/m figure of 0.817. L ¢..~.,¢t.., -flog ,1.

Starting current = 3 x 160A = 480 Amps.

Volt drop (Running) = 0.817 x160 x 50

= 6,5 Volts (Very Low)

Volt drop (Starting) = 0.817 x 480 x 50

= 19 Volts (Excellent)
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 How to Select an Electric Cable
Author‘s name: R. Hardie
Page 6 of 26

Table 6.2 (Facts and Figures booklet - page 38)

CURRENT RATING AND VOLTAGE DROP OF 3 AND 4 CORE PVC INSULATED CABLES WITH
STRANDED COPPER CONDUCTORS
_ — ——~ ~ __. —* -

AREA Z A SUSTAINED CURRENT RATING (A) 1 VOLT DROP

l mm“ ‘ ohm/km jl mV/A/m

oaounp l pucr A AIR 5

la\ 1,5 .__. _ 1
1 _
14,46
A .- A”_..~.A; _~_ ..
23 18 16 25,060
2,5 6,67 l 30 24 ‘ 24 1 15,363 4 41.
-2

, 4 ) 5,52 l 38 31 32 1 9,561

6 6,69 I 46 l 39 A 40 3 6,691
10 ‘ 2,19 64 I 52 54 ; 6,796
_7 _ J __ _____ ._

16 1,38 1‘ 62 A 67 ;\ 72 , 2,690
._ _2-=‘— —

l l

5, 25 0,6749 126 ‘ 101 116 1,515

l
‘ 65 0,6335 147 ‘ 120 \ 166 1,097 l

50 0,4718 176 l 144 l 15 7 0,817

._ if _
70 *2; i
1
.,r
0,6625
*7’. A AA» L
‘ .2
215 175 , 207 l 0,576
l
A 95 0,2460 257 210 256 0,427
(
1
_
120
_, _.. .
0,2012 292 239 296 0,646
l
150 ~i 0,1698 328 269 gi 666 l 0,294
185 l 0,1445 669 , 303 664 l 0,250
ea‘, _ =__ Re J . as
240
__
\ 0,1220
_.__ _____
_ . 7
l
,i_ . _ __.
422__
_ _
7 7, _ l
2__
348 , 447 , 0,211
300 0,1 090 472 397 509 l 0,189
. _ ’__ .__. "1 __,_l W. ___, . . , , _l

6
72>",-:52 2*?”-6.1165
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 How to Select an Electric Cable
Author's name: R. Hardie
Page 7 of 26

Table 6.3 (Facts and Figures booklet —- page 39)

CURRENT RATING AND VOLTAGE DROP OF 3 AND 4 CORE PVC INSULATED CABLES WITH SOUD
ALUMINIUM CONDUCTORS

I AREA 1, z A SUSTAINED cuaaenr RATING (A) vou‘ pace

\ mm? ohm/km mV/Aim

, , oaouno pucr ‘ lT
AIR 1
TTT T T T TTT’ K’ T W 1 T’ T" T H T ‘ ' W T T ' T P T TTT’ T T T" T,’ Tl
l

1 25 1,4446 98 79 88 6 2,502
35 1 1,0465 119 95 108 1,813
1 _, _ 6: —— :_ ~ _._ "7 __

50 0,7749 D 142 113 132 l 1,342

1 . *_,._
A
70 , 0,5666 A, 171 l 138 ‘ 164 0,966 l
l

l
, l
95 . 0,6964 1 204 165 201,__. 0,681
, _t\_ T T TTTT” T 7* l TOT” _ __ ,l_ _ ___ W H , _ W.
l‘ ‘

,_‘
.24
120 0,6146 235 189 264 l 0,545
l
_ — [ — ———— ___ — —— —‘ 7 ——

= 150 1 0,2607 263 213

l
1 270 0,452
— _ —— .. ____ — _, _ —;_— — —. —.
l

‘ 185 0,2133 295 240 308 0,369 I”

T_ T621100"
,__._..._
7 0,1706 0 l
,_ _. __,______,/I ,_ H _
340 278 A T T 662T T l T0,296‘T T.‘

1-

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0491.55
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 How to Select an Electric Cable
Author s name: R. I-Iardie
Page 8 of 26

(
lf the distance was 200 metres, then volt drop would have
been:

Voltage drop (Running) m 0.817 x 160A x 200

:: 26 Volts. (6,5% illegal)

Voltage drop(Starting) : 0.817 X 480 X 200

2 78 Volts. (19.5% Unacceptable
because motor may not start!)
Recall that Torque ‘X Voltagez

Larger cable sizes in this case could be calculated as follows:

Cable Size Volt Drop Starting

70mm? Copper: 0.576 x 480A x 200m 2 55 296mV

= 13.8%
(Perhaps too high)

95mm2 Copper: 0.427 x 480A x 200m x 40 992mV

= 10.2%
(Perhaps still too high)
120mm‘-'=‘ Copper: 0.348 x 4-80A x 200m : 38 4-08mV
: 8.4%
(Probably OK)

" 8
016155
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 How to Select an Electric Cable
Author s name R. Hardie
Page 9 of 26

150mm2 Copper: 0.294 x 480A x 200m 2 26 224mV

= 7.0%
(Probably OK)
185mm2 Copper: 0.250 x 480A x 200m 2 24 000mV
I = 6.0%
(More than OK)
240mm2 Copper: 0.211 x 480A x 200m : 20 256mV
m 5.0%
(More than OK)

At last a cable that meets the volt drop requirement.

lLl
CALCULATION VOLTDROP

A) Loads other than motors

Do not exceed 5% volt drop on full load current.

B) Motor loads --- 3 phase

DOL -— allow 20% volt drop at 6 x Full load current.

Star-Delta -- allow 5% volt drop at 2 x full load current.

Motor loads — 1 phase

Allow 20% volt drop at 8 x Full load current.

C) Special GEC Low starting current single phase motors .

._ ._ _ L. fig
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 How to Select an Electric Cable
Author s name: R. Hardie
Page 10 of 26

Allow 5% volt drop on 2 x Full load current for 7,5 kW and

4.5 Full load current for 4.5 kW.

ln general efficiency of 80% may be used, and power factor,

Cos 6 6 0,8.
2.

1222,2 /\.z:"‘ T’ q"""" r\

22.2
22>-I-E—— ';"'f>~i3t.':»

In practice it is sometimes easier to first calculate the volt drop

requirements, and then check whether the cable is large
enough.

% Volt drop x Voltage x 1000mV/V

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-- = mV/A/m
Current (A) x Distance (m)

Select a cable from the previous table with a volt drop

(mV/A/m) figure just smaller than the above calculated value.
Before accepting this size, check that the current rating of this
cable is adequate for the full load current required.

Using the previous example:

. (§"\v\J \
.1, “'6
5°/0 X 400V X 1 OOOITN
----------------------------=— = 0.21 mV/A/m required
480A x 200m

Corresponding cable x 24-0mm2 Copper cable

You must use this method with caution if you are close to the
grew
W 10
0151.55

6; Powe-rte h L
 How to Select an Electric Cable
Author’s name: R. Hardie
Page 11 of 26

supply — For example if the distance was only 10m, then

5% x 400V x 1 000mV/V
------------------------------ = 4,17mV/A/m
480A x 10m

Cable Size = 10m2 Copper cable

But this cable cannot carry 160A required full load current!

USE OF A HIGHER VOLTAGE

Problems sometimes occur when the distance is great, and the
cable becomes excessively large (and expensive) in order to
comply with volt drop requirements.

Then we must consider using a higher voltage.

The advantage of a higher system voltage, for example _ "KG
lnterdac 3 at 1.9/3.3kV is that: asaw 14%" *P‘~‘t’"°’T’<t"“" ‘*“"‘ 7
1. Current is lower for same power (smaller conductor).

2. Higher voltage drop is allowed (5% of 3.3kV = 165 Volts).

Naturally there would appear to be even greater advantage in

increasing the voltage to 6.6kV or even higher, 11kV, 22kV etc.
However, these cables become progressively more expensive
because of the MV dielectric system required, for stress control
reasons. 3.8 kV is the highest voltage that can be used cheaply
-- i.e no expensive dielectric system is required, just a thicker
insulation.

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 CABLES
The allowable current, or the current rating of an electric cable
is that current which will result in the conductor temperature
rising to the maximum operating temperature.

1;,» 49 For XLPE this is 9060

A-T22-It For PlLC this is 65°C

%..9-9» For PVC this is 70°C

When a cable is installed in a hot environment, for example

against a boiler, it stands to reason that the cable will have a
lower current rating than the same cable installed in cooler
conditions.
C. 4/ gpl 6"\jT
Brochure 536166 current ratings are based on the following
standard conditions:

Ground Temperature 25°C

Ambient Temperature 30°C

Ground Thermal resistivity (g) 1.2K.m/W

Depth of laying to top surface of cable or duct 0.8m

1 -
r;.Ztt2et..".a2i@=~4
046155
1. Powerteclt L3
 How to Select an Electric Cable
Author's name: R. Hardie
Page l3 of 26

CURRENT RATINGS ARE BASED ON THE FOLLOWING:

PAPER INSULATED CABLES

Maximum sustained conductor temperature ‘ 70°C 24

3 Ground Temperature 25°C

Ambient air temperature (free air-shaded) 30°C
l l
Ground Thermal Resistivity l 1,2K.m/W
i Depth of laying to top of cable or duct , 800 mm ll
l
9l

DERATING FACTORS FOR NON-STANDARD CONDITIONS

Depth of laying - multicore PlLC cables (up to 300mm?)

l ' l ' '

, Depth of laying ‘ Direct in ground In single way ducts

(mm)
800 1,00 1,00
1100 0,98 0,99
1250 0,96 0,97
1500 0,95 0,96
l

2000 0,92 0,94

ll

Ground Thermal Resistivity (Multi-core PILC cables)

l
‘ Thermal Resistivity 1 Direct in ground In single way ducts
A (Km/W)
1,0 1,07 1,03

1,5 0,92 0,95

2,0 0,84 0,89

>-
L-

2,5 0,76 0,84

CAIBLES
Powertech E3
 How to Select an Electric Cable
Author’s name: R. Hardie
Page l4 of 26

Grouping of PlLC cables in Horizontal Formation at standard depths of laying and in standard
soil conditions (multicore cables).

No of F Direct in ground In single way ducts

cables l l

1 In l “
group

A Axial spacing (mm) _ A A Axial spacing (mm)

l
1 1 Touching 150 , 300
L .
4-50 l 600 A Touching 300 450 600
. it
.77 gm’?
‘l

24 .
2
A
0,80
22-.-. 2,2,, l
0,85 0,89 0,90 0,92 0,88 0,91 ; 0,96
_ ,_,,_ 12,.
0,94
,A 3 ) 0,69 0,75
..l
0,80 0,84 1 0,66 0,80 0,84 0,67 0,89
4 0,63 0,70 0,77 0,80 0,64 0,75 0,81 0,64 0,87
5 0,57 0,66 i 0,76 0,76 0,61 0,71 0,77 0,62 0,65
6 .
0,55 0,63 0,71 0,76 0,80 ; 0,69 0,75 , 0,60 0,64
Ground Temperature derating factors

Maximum Ground Temperatures (°C)

Conductor
Temperature l

(7020) 24 —_— ___ —_ ——— 1 — —— —_ 7—~ _ ;_—_ _74 2 7

‘ 25 A 30 35 40 45
1 1,00 0,95 0,90 0,65 0,60
Air Temperature derating factors

Maximum Air Temperatures (°C)

Conductor
Temperature
(70°C)
I ti T TT TIT T T T F T TT T TT A

25 60 40 45 "
L
1,10 1,00 0,94 0,67 T 0,79

.
0581.55
Powe rtech U
 How to Select an Electric Cable
Author's name: R. Hardie
Page 15 of 26

_§i_2PE_I.NS,Ul_:_ATED,__QABLE§_

Maximum sustained conductor temperature 90°C

_..

Ground Temperature 2570

Ambient air temperature (free air-shaded) A 30°C

Ground Thermal Resistivity 1,2K.mlW

7 ': 2 ;_ _ — —— .

Depth of laying to top of cable or duct 600 mm

DERATING FACTORS FOR NON-STANDARD CONDITIONS

Derating factors of laying - multicore XLPE cables (up to 300mm2)

A Depth of laying I Direct in ground In single way ducts

l (mm) ~
500 - 800 1,00 A 1,00

850 - 1000 A 0,97 0,96

1050 - 1200 0,95 A 0,95
1250 — 1400 0,93 0,95
1450 - 1600 0,92 0,94

Ground thermal resistivity - multicore XLPE cables (up to 300mm’)

Thermal Resistivity I Direct in ground In single way ducts

, . (Km/W)
0,7 1,23 1,28

A C3 1,08 1,12

, 1.2 1,00 1,00

I 1,5 0,90 A 0,93
l

2,0
2224.

0,80 I 0,85
1lT T T an-1‘

I 2,5 0,72
l
0,80
3,
ll
ll
it
, 3,0 l 0,66 0,74
J.

15
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 How to Select an Electric Cable
Autl1or’s name: R. Hardie
Page 16 of 26

Grouping of XLPE cables in horizontal formation at standard depths of laying and in standard
soil conditions (multicore cables).

No of Direct in ground A in single way ducts

I cables
A I I1 A
l group
A22. 22.. . 2 -2 4 ~~ 4 ~ 2- W» 2 44 2 2 __~~22- 2. . 2 2. 2 41.

Axial spacing (mm) Axial spacing (mm)

l A l Al

if —— — _ —_ ;_ 7 — 2
f Touching A
————— — — 7 — — — — —— — .2
250
22 222222222
A 700
. "<72 *2 22 fie 2.22
I Touching —— .22 —— — 2 —— _ ‘ 47
250 W7
l 700
F
TIT l
l
‘‘ 2 0,79 0,85 A 0,67 0,67 0,91 A 0,93
A
l l

3
_2
I 0,69
_:2.2 .
Al 0,75
2 2.2222. 2. ..
I
.22
0,79
22
iAf
L2 2
0,60 .2. l2
0,86 0,91
4 0,66 l 0,66 0,75 0,75 0,80 0,87
» 5 0,56 0,64 A 0,72 * 0,72 E 0,78 I 0,86
6 0,55 0,60 0,69 I 0,69 0,74 0,66

Ground temperature derating factors

A Maximum l Ground Temperatures (°C)

Conductor
Temperature
(9°°C) l _ <—— 2. 2 222 2 ——— —41-

25 A 60 65 40 45 l
l

1 .
T’)
1,0 0,96 0,92 0,66 0,84

Air Temperature derating factors

Maximum Air Temperatures (°C)

Conductor
Temperature
A (90°C) l
Al ~22. 42 . .4-.. 2.. 2 2
‘ 60 65 40 45 50
A 1,0 0,95 0,69 0,64 0,76

16
OBLES
tr; Powerteclt E;
 How to Select an Electric Cable
Author’s name: R. Hardic
Page 17 of 26

PVC I_NSULl£I'_ED Cfi_\__B_LES

* Maximum sustained conductor temperature 70°C

Ground Temperature 25°C
Ambient air temperature (free air-shaded) 30°C
‘ Ground Thermal Resistivity \ 1,2K.m/W

Depth of laying to top of cable or duct l 500 mm

SUSTAINED CURRENT RATING FACTORS FOR NON-STANDARD CONDITIONS

Derating factors for depth of laying - multicore cables (up to 300mm’)

Depth of laying Direct in ground ln single way ducts

(mm) ~
500 1,00 1,00
.l

800 0,97 0,97

1000 0,95 0,96
1250 0,94 0,95
1500 0,93 0,94
2000 0,92 0,93

Derating factors for ground thermal resistivity (multicore cables)

Thermal Resistivity Direct in ground ‘ In single way ducts

(Km/W)

1,00 1,08 1,04

1,5 i 0,93 0,96
l 2,0 0,83 0,88
2,5 0,78 0,87

_ 17
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 How to Select an Electric Cable
Auth0r’s name: R. Hardie
Page 18 of 26

Derating factors for grouping of cables in horizontal formation, at standard depths of laying
and in standard soil conditions. Multicore cables (up to
300mm?)
_, ffl i ,_ ffi, rrfeiee ___,_,,,,*, W W ,_ ,1 _ _____, 1 99*, __ i

No of Q Direct in ground In single way ducts

cables
in
QFOUP l ‘

Axial spacing (mm) l Axial spacing (mm)

‘ i I , ,1 i
‘
l
,“_ ___ __
A Touching , 150 300 450 600 Touching 300 450 600 l
*1 ,_,,_» ———— " *1 _t_: __:L_ ____fl’ I~ ' _;_'_ _.‘-
l l

2 i 0,81 0,87 0,91 0,93 0,94 L 0,90 0,93 i 0,95 l 0,96

___:,____ WT _ _ _ __ “ _ ____f ___ ___ i __T_________:____

3 0,70 0,78 1 0,84 0,87 0,90 , 0,82 ‘ 0,87 l 0,90 l 0,99

I I’ T7 I 7 fil "7
4 0,83 ‘ 0,74 0,81 ;‘ 0,88 0,89 0,78 5 0,85 A, 0,89 0,91
1 ,l l ,l ir

5 0,59 0,70
_
0,78 l
0,88 ‘ 0,87
— ,1 ____;, 7 — 4
0,75 § 0,82 0,87 I 0,90
‘F l l 77

8 l 0,55 A 0,87 I 0,78 0,82 0,88 0,72 9,81 0,88 8,90

Ground Temperature derating factors ~ multicore (up to 300mm?)

Maximum ‘ Ground Temperatures (°C)

Conductor
Temperature

25 30 35 40 I

0,90 0,85 0,80 0,74 l

Air Temperature derating factors

Maximum Air Temperatures (°C)

Conductor
Temperature
(70°C)
__'_, , , ___,, We A t _____,_ We
i l t i
30 35 40 45

1,00 0,94 0,87 0,79 ,

18
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‘;. \ . .-»\. '1:. ,- Powertech [.3
 How to Select an Electric Cable
Author’s name: R. Hardie
Page 19 of 26

Derating factors for grouping of multicore cables installed horizontally in air

— — ;— — — — — __—_:__ ___—_ __:— _ —— —_‘ _

No of cables 1 I 2 I 3 I 6 j 9

Condition DERATING FACTOR

‘QI Cables touching
" l. 1 0, 9 0,85 0,8 0,75
L Clearance D* between Cables 1 0,95 0,9 0,88 0,85 ,

*D is the overall diameter of one cable

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 How to Select an Electric Cable
Author s name: R. Hardie
Page 20 of 26

FAULT CURRENT
This topic is normally very important with higher voltages than
LV.

Two types of fault current need to be considered:

1. Short circuit current (sometimes called symmetrical fault
current).
2. Earth fault current (sometimes called asymmetrical fault
current). 1

SHORT CIRCUIT CURRENT

When we experience a fault on an electrical system, the

protection equipment will detect the fault and trip out the faulty
circuit. It cannot however trip instantaneously, and a delay, (of
up to a few seconds) will occur.
The formula for the short circuit current withstand capability of
an electric cable is:
A KxA
lsc == -------
1/1
Where lsc = Short circuit rating of cable (kA)
A = Area of conductor (mmz)
t = Time to trip (in seconds)
K : 115 for PVC, Copper conductor
= 76 for PVC, Aluminium conductor
= 115 for PAPER, Copper conductor
= 76 for PAPER, Aluminium conductor
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 I-low to Select an Electric Cable
Author s name: R. I-lardie
Page 21 of 26

K= 143 for XLPE, Copper conductor

= 92 XLPE, Aluminium conductor
Example: For a 7Omm2, PVC insulated Copper conductor
the 1 second short circuit rating is:-

115X70 = 8,05 kA
lsc = ---------
~11
If the protection is fast, (say 0.2 seconds) then the conductor
will have a 0.2 second short circuit rating of:

115x70 = 18 kA
1/0.2
EARTH FAULT CURRENT

If the phase conductor comes into contact with the earth conductor
(lead sheath, copper tape or armour) then we must ensure that this
earth conductor can survive the resulting fault current.
Again the formula is lei = KxA
1/1
Where K Depends on the earth path material. (Steel wire
armour (K=42), lead sheath (K=24), copper tape
(K=143) or Aluminium wire armour (K=76)
A = Cross-sectional area of earth path.
t = Fault duration in seconds.

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 How to Select an Electric Cable
Author’s name: R. Hardie
Page 22 of 26

EXAMPLE OF CABLE SELECTION FOR MEDIUM

VOLTAGE (11kV)
We wish to supply a 2MVA, 11kV transformer from an Eskom supply
point which is 3km away. We are to use an underground Paper
Insulated, Copper conductor cable.
£5 K.Q4~»i—'Lw '\*‘\v‘ ‘STEI’ kw

The depth of burial of the cable is 1.25m. Ground thermal resistance

is 2 K.m/W. The ground temperature is 25°C and there are no other
cables in the trench.
Short circuit level may be assumed to be 25OMVA, and the earth
fault level 100MVA, and it may be assumed that a fault will be
cleared in 1/2 second.
Using the previous formulae:

Ifull load '7'" _.._....._.___._________2

O00
1/8 X 11 000
= 105 AFRPS.

Derating factor for Depth of Burial at 1.25m is 0.96.

Derating factor for Soil Thermal Resistivity at 2 K.m/\N is 0.84.
Derating factor for Ground Temperature of 25°C is 1.00.
Total derating factor = 096x0B4x100
= 0.806
Either derate the standard cable current rating as given in our ,._._

catalogues by multiplying this value by the product of the derating

factors as calculated above, or increase the required load current by
dividing the load current by the derating factor.
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 How to Select an Electric Cable
Author's name: R. Hardie
Page 23 of 26

Irequked 105 + 0.806

130 Amps

Facts 8 Figures page 28, or our Paper Insulated Cable catalogue

shows that:-
A 35mm2 Copper conductor cable would be capable of carrying this
load(130A)

Cable size required is thus 35mm2, Copper conductors, 3 Core

general purpose belted cable.

Checking for volt drog: (For academic reasons only)

Vdrop = Z x \/3 x I x distance 7 M A3:

E 0.62729/km X 1.78 X 105A X 3000m earl A‘ " " “ “'
= 341.8 Volts = (2.8% of 11kV) -1; gar-7 2 \f 8 _/
Volt drop is seldom a problem at Medium Voltage, even for long runs
of small conductor size as shown above. CW» .».».»u. 1-84? <<»>@-r-~»& “ea 1*“ ‘“""“ Tm”
."\.r-€’l--Q-/\-~ ¢:fi__..r—-1.1-wit

Checking for fault current survival:

Prospective symmetrical (Short circuit) current.
F Q fk E/e~I5l1r'3Wv~.»*

250 MVA 3’
Isc \f3x11000
13.137kA

15"“ ;li:s=r.‘mn'_1. 2"‘ 8.1.-ht".-2'.

OQBLES
Powertectr I13
 I-low to Select an Electric Cable
Author s name: R. Hardie
Page 24 of 26

The selected cable short circuit current withstand is:-

35 x Factor
lsc = --------------— Factor is 116 for paper insulated
\/t copper conductors

35 x 116 13;; HST g

_.._-- “I S. €>‘°t2_lLA
The ‘A2 second rating is thus ----------- = 5 742 A xi, .5;
\/0.5

This cable will not survive the prospective short circuit current of
13 137 A.

Minimum Conductor size required :- “X” x 116 “>< ” .. no

= 18187 ”r:.~~ "“?"?’7
1/0.5 X
__,
___J 89 55../{ M
FIX”
= 8Omm2

Smallest standard size is thus a 95mm2 Copper conductor. This has

a current rating of 235 Amps under standard conditions.

Prospective (earth) fault current:

100 MVA

v’8><11000
= 5254 A
\_

F ‘ _ fg _ Al _, . PL/i,Q_L/,_J,.. 8/~»Cr-—1~<~2»,I“
10 21-PIA. M v’ A/‘~’l'*(’~*" 1 “ft
24
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 How to Select an Electric Cable
Author s name: R. Hardie
Page 25 of 26

We now need to calculate the earth fault capability of our cable. As

this will be carried by the lead sheath, we need to calculate the lead
sheath cross sectional area.

95mm2 (table 17) -- Diameter over lead 238mm K y

Lead Thickness = 1,8 mm t_c~:s-~vr.-59>
Lead Area E200 mmz

Area x K lead
Cable earth fault current withstand is = ------------------
~/0.5
200 x 24

10.5
m 6 800 A (for 0.5 second)

This cable will survive the prospective earth fault current of 5 254 A.

In many cases the cable conductor size is required to be larger than

dictated by the full load current, in order to survive short circuit
conditions
The use of large conductors can sometimes be avoided
by improving the speed of protection, and in the case of earth fault
current, by the use of more sensitive earth fault protection.

25
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.- 1:; Powertech £3
 How to Select an Electric Cable
Author’s name: R. Hardie
Page 26 of 26

BENDING RADIUS 1
7 -»~r cur"
-u
o

l\P8ver over bend an electric cable.

The following are values of bending radius that should not be
exceeded.
Up to and 22 kV
Including I and
I 11 kV 33 kV
PILC Single Core ;20xd 25xd
Multicore 12xd 15xd
PVC Single Core BXCI -
Multicore 10xd Y -
we (XLPE Single Core 17xd 17xd
_ Multicore 15xd 15xd

Where d = overall diameter. of cable.

‘v
Minium Bending Radius
= Factor x Cable OD

_ 22.._......... ...l ....

Infringing the minimum bending radius, will result in premature

cable failure —This will probably not happen during commissioning
but years later.

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2." .1‘ -. *. '=. Powerrech Ill‘
Medium Voltage Cables Grid Substation Construction Projects

1. INTRODUCTION
This document provides the 33 kV medium voltage cable sizing calculation for the Sri Jayawardenapura Grid
Substation. The cable calculations are done as per the IEC standards.

2. DESIGN INPUTS AND DESIGN BASIS

2.1. Design Inputs

SYSTEM PARAMETERS
(a) Nominal Voltage 33 kV
(b) Maximum Continuous Voltage 36 kV
(c) System Frequency 50 Hz
(d) Method of Earthing Effectively
(e) System fault current 25 kA
(f) Fault duration 1s

SERVICE CONDITIONS
(a) Annual Average Ambient Temperature 30 oC
(b) Maximum Ambient Temperature 40 oC
(c) Maximum relative humidity 90 %
(d) Maximum Short time temperature of the 250 0C
conductor
(e) Cable laying method Direct Burried
(f) Environmental conditions Humid tropical climate with polluted atmosphere
(g) Operational altitude From M.S.L. to 1900 m
(h) Average ground temperature 30 oC
(i) Depth of laying 1.1m

2.2. Design Calculations and Equations.

· Continuous Current carrying capacity calculation
This is calculated as per the IEC 60502-2(2005) standard. Rated current under standard conditions
are derated according to the actual operating conditions and the actual current carrying capacity is
derived. This current should be greater than the operating current of the circuit.