HZL-BTN-ELE-DS-SY-037

LT CABLE SIZING CALCULATION

PMCC TO MCC INCOMER
1.00 INPUT DATA
1.01 Feeder Load

460

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

50

1.04 AC resistance of the cable at 90C

0.129

1.05 Reactance of the cable at 50Hz

0.0705 / km

1.06 Allowable Voltage Drop

1.07 Current derating factor

0.65

/ km
%

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

3 x V

460 / 0.8

3 x 0.415

800

Size of 300 Sq.mm 3.5 core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

300

1.0

455 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving at the capacity

= 455x3x0.65

2.03 current carrying capacity of 300sq.mm,3Run cable

887 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

800

240

50

1.94
1.94

((0.000129 x 0.8) + (0.0000705 x 0.6))

100

0.81

With in the permissible limits of 5% voltage drop hence ok

3.02 Short Time rating of the Cable
s
300
Iw
(ACB Operated)
=
=
= 22.7 KA/0.2Sec
13.2xt
13.2*1
3.03
3 runs of 1.1kV grade, 3.5C x300 sq.mm, Al conductor, Armoured, XLPE cable is selected

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HZL-BTN-ELE-DS-SY-037
PMCC TO Crusher Building EOT Crane
1.00 INPUT DATA
1.01 Feeder Load

76.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

45

1.04 AC resistance of the cable at 90C

0.409

1.05 Reactance of the cable at 50Hz

0.0724 / km

/ km

1.06 Allowable Voltage Drop at Normal Running Cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
76.5 / 0.8

P
IFL

=
3 x V x

2.02

140

0.95x3 x 0.415

Size of 95 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
95

1.0

221 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving at the capacity

= 0.65
= 221x1x0.65

2.03 Current carrying capacity of 95 sq.mm1 Run Cable

= 144

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

140
Vdrop

((0.000409 x 0.8) + (0.0000724 x 0.6))

x
1

Vdrop

%Vdrop

2.335
2.335
240

V
x

100

0.98

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

840

( 6 Times the full load current)

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HZL-BTN-ELE-DS-SY-037
Drop at the time of Starting
840
Vdrop

((0.000409 x 0.8) + (0.0000724 x 0.6))

45

1
Vdrop

%Vdrop

14.01
14.01

240

100

5.84

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

95

13.2xt

= 16.1

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x95sq.mm, Al conductor, Armoured, XLPE cable is selected
PMCC TO Conveyor 01
1.00 INPUT DATA
1.01 Feeder Load

132

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

165

1.04 AC resistance of the cable at 90C

0.129

1.05 Reactance of the cable at 50Hz

0.0705 / km

/ km

1.06 Allowable Voltage Drop at Normal running Cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
132 / 0.8

P
IFL

=
3 x V x

2.02

242

0.95x3 x 0.415

Size of 300 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
300

1.0

455 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 455x1x0.65

2.03 Current carrying capacity of 300 sq.mm1 Run Cable

=
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x
n
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296 A

HZL-BTN-ELE-DS-SY-037
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

242
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

165

1
Vdrop

%Vdrop

5.81
5.81

240

100

2.43

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
= 1452 A

DOL or Squirrel Cage

( 6 Times the full load current)

Drop at the time of Starting

1452
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

165

1
Vdrop

%Vdrop

34.859

34.859

240

100

14.53

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

300

13.2xt

KA/Sec

= 22.7

13.2*1

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x300sq.mm, Al conductor, Armoured, XLPE cable is selected
PMCC TO Conveyor 02
1.00 INPUT DATA
1.01 Feeder Load

90

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

270

1.04 AC resistance of the cable at 90C

0.264

1.05 Reactance of the cable at 50Hz

0.0716 / km

/ km

1.06 Allowable Voltage Drop at Normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

90 / 0.8
=

3 x V x

165

0.95x3 x 0.415

Size of 150 Sq.mm 3.5core Aluminium cable is selected for checking.

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HZL-BTN-ELE-DS-SY-037

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

150

1.0

292 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 292x2x0.65

2.03 Current carrying capacity of 150 sq.mm2 Run Cable

380 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

165
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

270

2
Vdrop

%Vdrop

5.661

5.661

240

100

2.36

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

990

( 6 Times the full load current)

Drop at the time of Starting

990
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

270

2
Vdrop

%Vdrop

33.968

33.968

240

100

14.16

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

150
13.2*.2

= 25.4

KA/0.2Sec

(Fuse Operated)

3.04 2 run of 1.1kV grade, 3.5C x150sq.mm, Al conductor, Armoured, XLPE cable is selected

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HZL-BTN-ELE-DS-SY-037
PMCC TO Conveyor 12 - Stream 2 Feed conveyor
1.00 INPUT DATA
1.01 Feeder Load

75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

305

1.04 AC resistance of the cable at 90C

0.264

1.05 Reactance of the cable at 50Hz

0.0716 / km

/ km

1.06 Allowable Voltage Drop at Normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

75 / 0.8

3 x V x

137

0.95x3 x 0.415

Size of 150 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

150

1.0

292 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables
= 0.86
Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 292x2x0.65

2.03 Current carrying capacity of 150 sq.mm2 Run Cable

380 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

3 x IFL
x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

137
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

2
Vdrop

%Vdrop

5.31
5.31
240

V
x

100

2.22

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Short Time rating of the Cable
Check for Starting Current
DOL or Squirrel Cage

822

( 6 Times the full load current)

7 of 284

305

HZL-BTN-ELE-DS-SY-037
Drop at the time of Starting
822
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

305

2
Vdrop

%Vdrop

31.86

31.86

240

100

13.28

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

150

13.2xt

= 25.4

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 2 run of 1.1kV grade, 3.5C x150sq.mm, Al conductor, Armoured, XLPE cable is selected
PMCC TO AUX. SWITCH BOARD
1.00 INPUT DATA
1.01 Feeder Load

230

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

25

1.04 AC resistance of the cable at 90C

0.21

1.05 Reactance of the cable at 50Hz

/ km

0.0718 / km

1.06 Allowable Voltage Drop

1.07 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

P
3 x V

230 / 0.8

3 x 0.415

400

Size of 185 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 337x2x0.65

2.03 current carrying capacity of 185sq.mm,2Run cable

=
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL
n

x (R cos + X sin) x

8 of 284

438 A

HZL-BTN-ELE-DS-SY-037
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

400

2
1.055

((0.00021 x 0.8) + (0.0000718 x 0.6))

25

1.055

240

100

0.44

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Short Time rating of the Cable
Iw
3.03

185

13.2xt

KA/0.2Sec

= 31.3

13.2*.2

(Fuse Operated)

2 runs of 1.1kV grade, 3.5C x185 sq.mm, Al conductor, Armoured, XLPE cable is selected
MCC TO PRIMARY GYRATORY CRUSHER LOCAL PANEL

1.00 INPUT DATA

1.01 Feeder Load
1.02 Voltage rating

P
VT

=
=

40.2
0.415

1.03 Length of the cable

35

1.04 AC resistance of the cable at 90C

1.11

1.05 Reactance of the cable at 50Hz

=
=

1.06 Allowable Voltage Drop

kW
kV
m
/ km

0.0783 / km
5

2.00 Calculation
2.01 Full load current rating of the Feeder
40.2 / 0.8

P
IFL

=
3 x V x

2.02

74

0.95x3 x 0.415

Size of 35 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables
= 0.86
Reduction Factor
= 0.9
Factor for Non linear loads
= 0.8
Total factor to be applied for arriving the capacity = 0.65
= 117x1x0.65
2.03 Current carrying capacity of 35 sq.mm1 Run Cable
= 76
A
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x
n

Where,
cos
sin

=
=

0.8 (Assumed)
0.6
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HZL-BTN-ELE-DS-SY-037
74
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

35

1
Vdrop

%Vdrop

2.422
2.422

240

100

1.01

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Short Time rating of the Cable
s
35
Iw
=
=
= 5.93 KA/0.2Sec
13.2xt
13.2*.2

(Fuse Operated)

3.03 CABLE SIZE :

1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
PRIMZRY GYRATOR CRUSHER SPIDER LUBRICATION SYSTEM
1.00 INPUT DATA
1.01 Feeder Load

1.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

15

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop at Normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

2.00 Calculation
2.01 Full load current rating of the Feeder

0.65

P
IFL

1.5 / 0.8

=
3 x V x

=
0.95x3 x 0.415

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65
46 A
=

2.03 Current carrying capacity of 16 sq.mm,1 Run Cable

3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x
n

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HZL-BTN-ELE-DS-SY-037
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

3
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

15

1
Vdrop

%Vdrop

0.09

0.09

240

100

0.04

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

18

( 6 Times the full load current)

Drop at the time of Starting

18
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

15

1
Vdrop

%Vdrop

0.54

0.54

240

100

0.23

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

16

13.2xt

13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
PRIMARY GYRATOR CRUSHER OVER PRESSURE DUST SYSTEM AIR BLOWER
1.00 INPUT DATA
1.01 Feeder Load

1.1

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

15

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop at Normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

2.00 Calculation
2.01 Full load current rating of the Feeder

0.65

P
IFL

1.1 / 0.8
=

3 x V x

=
0.95x3 x 0.415

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

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HZL-BTN-ELE-DS-SY-037
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm,1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

2
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

15

1
Vdrop

%Vdrop

0.06

0.06

240

100

0.03

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

12

( 6 Times the full load current)

Drop at the time of Starting

12
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

15

1
Vdrop

%Vdrop

0.36

0.36

240

100

0.15

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

3.03 Short Time rating of the Cable

Iw

s
13.2xt

16
13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected

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HZL-BTN-ELE-DS-SY-037
Primary Gyratory Crusher lube pump
1.00 INPUT DATA
1.01 Feeder Load

5.6

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

15

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop at Normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.6 / 0.8

=
3 x V x

2.02

0.95x3 x 0.415

Size of Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

70 A

1.0

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm,1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

10
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

1
Vdrop

%Vdrop

0.3
0.3
240

V
x

100

0.13

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

60

( 6 Times the full load current)

13 of 284

15

HZL-BTN-ELE-DS-SY-037

Drop at the time of Starting

60
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

15

1
Vdrop

%Vdrop

1.8

1.8

240

100

0.75

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

3.03 Short Time rating of the Cable

Iw

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Primary Gyratory Crusher lube oil heater
1.00 INPUT DATA
1.01 Feeder Load
1.02 Voltage rating

P
VT

=
=

2
0.415

1.03 Length of the cable

15

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

kW
kV
m
/ km

0.0808 / km

1.06 Allowable Voltage Drop at Normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

2 / 0.8
=

3 x V x

=
0.95x3 x 0.415

Size of 16 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm,1 Run Cable

= 0.65
= 70x1x0.65
=

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HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

4
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

15

1
Vdrop

%Vdrop

0.12

0.12

240

100

0.05

With in the Permissible limit of 15% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

24

( 6 Times the full load current)

Drop at the time of Starting

24
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

15

1
Vdrop

%Vdrop

0.72

0.72

240

100

0.3

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

16
13.2*.2

KA/0.2Sec

= 2.71

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
primary gyratory crusher air/oil coolers
1.00 INPUT DATA
1.01 Feeder Load

11

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

15

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop at Normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

15 of 284

HZL-BTN-ELE-DS-SY-037
2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

11 / 0.8

3 x V x

20

0.95x3 x 0.415

Size of 16 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm,1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

20
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

15

1
Vdrop

%Vdrop

0.6
0.6
240

V
x

100

0.25

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

120

( 6 Times the full load current)

Drop at the time of Starting

120
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

15

1
Vdrop

%Vdrop

3.601
3.601
240

100

1.51

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
16 of 284

HZL-BTN-ELE-DS-SY-037
3.03 Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
MPS PUMP FOR MPS SYSTEM
1.00 INPUT DATA
1.01 Feeder Load

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

15

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop at Normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

4 / 0.8

=
3 x V x

=
0.95x3 x 0.415

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables
= 0.86
Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 179x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

116 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

7
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

1
17 of 284

15

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

0.21

0.21

240

100

0.09

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

42
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

15

1
Vdrop

%Vdrop

1.26

1.26

240

100

0.53

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

16

13.2xt

13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Primary Crusher Product Apron Feeder (VFD)
1.00 INPUT DATA
1.01 Feeder Load

55

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

50

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at Normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

55 / 0.8
=

3 x V x

101

0.95x3 x 0.415

Size of 70 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

18 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 179x1x0.65

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

116 A

=
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

101
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

50

1
Vdrop

%Vdrop

2.507

2.507

240

100

1.05

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
For VFD

152

A ( 1.5 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

151.5

1
3.76

((0.000565 x 0.8) + (0.000074 x 0.6))

50

3.76

240

100

1.57

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

70
13.2*.2

= 11.9

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
Metal Detector conveyor 1
1.00 INPUT DATA
1.01 Feeder Load

0.04

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

165

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

19 of 284

0.0808 / km

HZL-BTN-ELE-DS-SY-037
1.06 Allowable Voltage Drop at Normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

0.04 / 0.9

=
3 x V x

2.02

0.065

0.95x3 x 0.415

Size of Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

70 A

1.0

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

0.065
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

165

1
Vdrop

%Vdrop

0.021
0.021
240

100

0.01

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
= 0.39 A

DOL or Squirrel Cage

( 6 Times the full load current)

Drop at the time of Starting

0.39
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

1
Vdrop

%Vdrop

0.129
0.129
240

V
x

100

=
20 of 284

0.06

165

HZL-BTN-ELE-DS-SY-037
With in the Permissible limit of 15% voltage drop hence ok
It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

16

13.2xt

(Fuse Operated)

KA/0.2Sec

= 2.71

13.2*.2

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
MCC TO BELT MAGNET CONVEYOR 01 - BELT DRIVE
1.00 INPUT DATA
1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

165

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop at Normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

3.7 / 0.8

=
3 x 0.415

3 x V x
2.02

Size of 16 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Current Rating at 35C
Cable size
Temperature 35C
16

70 A

1.0

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

= 46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

6
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

21 of 284

165

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

1.98

1.98

240

100

0.83

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

36

( 6 Times the full load current)

Drop at the time of Starting

36
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

165

1
Vdrop

%Vdrop

11.883

11.883

240

100

4.96

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

16

13.2xt

KA/0.2Sec

= 2.71

13.2*.2

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Primary Crusher area spillage pump
1.00 INPUT DATA
1.01 Feeder Load

30

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

36

1.04 AC resistance of the cable at 90C

1.11

1.05 Reactance of the cable at 50Hz

/ km

0.0783 / km

1.06 Allowable Voltage Drop at Normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

55

2.00 Calculation
2.01 Full load current rating of the Feeder
30 / 0.8

P
IFL

=
3 x V x

0.95x3 x 0.415

Size of 35 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

22 of 284

HZL-BTN-ELE-DS-SY-037
Total factor to be applied for arriving at the capacity

= 0.65
= 117x1x0.65

2.03 Current carrying capacity of 35 sq.mm,1 Run Cable

76

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

55
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

36

1
Vdrop

%Vdrop

1.851

1.851

240

100

0.78

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

330

( 6 Times the full load current)

Drop at the time of Starting

330
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

36

1
Vdrop

%Vdrop

11.108
11.108

240

100

4.63

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

3.03 Short Time rating of the Cable

Iw

s
13.2xt

35
13.2*.2

= 5.93

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
Apron Feeder Ventilation System Exhaust Fan
1.00 INPUT DATA
1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

60

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

1.06 Allowable Voltage Drop at normal running cond.

23 of 284

/ km

0.0808 / km
2.5

HZL-BTN-ELE-DS-SY-037
1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 / 0.8
=

=
0.95x3 x 0.415

3 x V x

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

10
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

60

1
Vdrop

%Vdrop

1.2
1.2
240

V
x

100

0.5

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

1
Vdrop

%Vdrop

7.202
7.202
240

100

3.01

With in the Permissible limit of 15% voltage drop hence ok

24 of 284

60

HZL-BTN-ELE-DS-SY-037

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Apron Feeder Ventilation System Supply Fan
1.00 INPUT DATA
1.01 Feeder Load

11

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

60

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

20

2.00 Calculation
2.01 Full load current rating of the Feeder
11 / 0.8

P
IFL

=
0.95x3 x 0.415

3 x V x

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

20
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

1
25 of 284

60

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

2.401

2.401

240

100

1.01

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

120

( 6 Times the full load current)

Drop at the time of Starting

120
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

60

1
Vdrop

%Vdrop

14.403

14.403

240

100

6.01

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
CV - 01 Ventilation System Exhaust Fan
1.00 INPUT DATA
1.01 Feeder Load

2.2

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

165

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
2.2 / 0.8

P
IFL

=
0.95x3 x 0.415

3 x V x

Size of 16 Sq.mm 4core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

26 of 284

= 0.65

HZL-BTN-ELE-DS-SY-037

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

4
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

165

1
Vdrop

%Vdrop

1.32

1.32

240

100

0.55

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

24

( 6 Times the full load current)

Drop at the time of Starting

24
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

165

1
Vdrop

%Vdrop

7.922

7.922

240

100

3.31

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

16
13.2*.2

= 2.71

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
CV - 01 Ventilation System Supply Fan
1.00 INPUT DATA
1.01 Feeder Load

2.2

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

165

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27 of 284

HZL-BTN-ELE-DS-SY-037

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

2.2 / 0.8
=

=
3 x V x

0.95x3 x 0.415

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

4
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

165

1
Vdrop

%Vdrop

1.32
1.32
240

V
x

100

0.55

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

24

( 6 Times the full load current)

Drop at the time of Starting

24
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

165

1
Vdrop

%Vdrop

7.922
7.922
240

V
x

100

3.31

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
28 of 284

HZL-BTN-ELE-DS-SY-037
3.03 Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
COSP Ventilation Exhaust Fan
1.00 INPUT DATA
1.01 Feeder Load

7.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

257

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

14

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

7.5 / 0.8
=

3 x V x

0.95x3 x 0.415

Size of 25 Sq.mm 4core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 96x1x0.65

2.03 Current carrying capacity of 25 sq.mm1 Run Cable

62

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

14
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

1
Vdrop

4.578

V
29 of 284

257

HZL-BTN-ELE-DS-SY-037
%Vdrop

4.578

240

100

1.91

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

84

( 6 Times the full load current)

Drop at the time of Starting

84
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

257

1
Vdrop

%Vdrop

27.466

27.466

240

100

11.45

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

25

13.2xt

= 4.23

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected
COSP Ventilation Supply Fan
1.00 INPUT DATA
1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

257

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

3.7 / 0.8
=

=
0.95x3 x 0.415

3 x V x

Size of 16 Sq.mm 4core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

= 0.65
= 70x1x0.65
=

30 of 284

46

HZL-BTN-ELE-DS-SY-037

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

7
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

257

1
Vdrop

%Vdrop

3.599

3.599

240

100

1.5

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

42
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

257

1
Vdrop

%Vdrop

21.593

21.593

240

100

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

16
13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
PCH AREA DSP PUMPS
1.00 INPUT DATA
1.01 Feeder Load
1.02 Voltage rating

P
VT

=
=

11
0.415

1.03 Length of the cable

48

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

kW
kV
m
/ km

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

31 of 284

HZL-BTN-ELE-DS-SY-037
2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

11 / 0.8

3 x V x

20

0.95x3 x 0.415

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables
= 0.86
Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

20
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

48

1
Vdrop

%Vdrop

1.92
1.92
240

V
x

100

0.8

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

120

( 6 Times the full load current)

Drop at the time of Starting

120
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

1
Vdrop

%Vdrop

11.523
11.523
240

V
x

100

4.81

With in the Permissible limit of 15% voltage drop hence ok

32 of 284

48

HZL-BTN-ELE-DS-SY-037

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

16

= 2.71 KA/0.2Sec
(Fuse Operated)
13.2xt
13.2*.2
3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
MOTORISED FLOPPER GATE
1.00 INPUT DATA
1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

50

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
5.5 / 0.8

P
IFL

=
0.95x3 x 0.415

3 x V x

Size of 16 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65
46 A
=

2.03 Current carrying capacity of 16 sq.mm,1 Run Cable

3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

10
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

33 of 284

50

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

240

100

0.42

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

50

1
Vdrop

%Vdrop

6.001

6.001

240

100

2.51

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Conveyor 4 - Stokpile feed conveyor with tripper car
1.00 INPUT DATA
1.01 Feeder Load

45

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

334

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

82

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

45 / 0.8
=

3 x V x

=
0.95x3 x 0.415

Size of 185 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

34 of 284

= 0.65

HZL-BTN-ELE-DS-SY-037

= 337x1x0.65
= 219 A

2.03 Current carrying capacity of 185 sq.mm1 Run Cable

3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

82
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

334

1
Vdrop

%Vdrop

5.781

5.781

240

100

2.41

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

492

( 6 Times the full load current)

Drop at the time of Starting

492
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

334

1
Vdrop

%Vdrop

34.686

34.686

240

100

14.46

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

185

KA/0.2Sec

= 31.3

13.2*.2

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected
Tripper car
1.00 INPUT DATA
1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

260

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

35 of 284

HZL-BTN-ELE-DS-SY-037
2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

3.7 / 0.8

=
3 x V x

0.95x3 x 0.415

Size of 16 Sq.mm 4core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

7
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

260

1
Vdrop

%Vdrop

3.641
3.641
240

V
x

100

1.52

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

42
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

260

1
Vdrop

%Vdrop

21.845
21.845
240

100

9.11

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

36 of 284

HZL-BTN-ELE-DS-SY-037
3.03 Short Time rating of the Cable
Iw

16

13.2xt

KA/0.2Sec

= 2.71

13.2*.2

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Wet Type Fan in PCH MCC
1.00 INPUT DATA
1.01 Feeder Load

2.23

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

20

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

2.23 / 0.8
=

3 x V x

0.95x3 x 0.415

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

4
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

1
Vdrop

0.16

V
37 of 284

20

HZL-BTN-ELE-DS-SY-037

%Vdrop

0.16

240

100

0.07

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

24

( 6 Times the full load current)

Drop at the time of Starting

24
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

20

1
Vdrop

%Vdrop

0.96

0.96

240

100

0.4

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Water Pump in B03 - PMC - 112
1.00 INPUT DATA
1.01 Feeder Load

1.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

50

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

1.5 / 0.8
=

=
3 x V x

0.95x3 x 0.415

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

38 of 284

= 0.65

HZL-BTN-ELE-DS-SY-037
= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

3
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

50

1
Vdrop

%Vdrop

0.3

0.3

240

100

0.13

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

18

( 6 Times the full load current)

Drop at the time of Starting

18
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

50

1
Vdrop

%Vdrop

1.8

1.8

240

100

0.75

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

16
13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
GSS TO PCH MLDB
1.00 INPUT DATA
1.01 Feeder Load

100

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

1100

1.04 AC resistance of the cable at 90C

0.129

/ km

1.05 Reactance of the cable at 50Hz

0.0705 / km

1.06 Allowable Voltage Drop

1.07 Current derating factors

0.65

39 of 284

kVA

HZL-BTN-ELE-DS-SY-037
2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

100

3 x V

139

3 x 0.415

Size of 300 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

300

1.0

455 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 455x2x0.65

2.03 current carrying capacity of 300sq.mm,2Run cable

592 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

139
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

1100

2
Vdrop

%Vdrop

11.123

11.123

240

100

4.64

With in the Permissible limit of 5% voltage drop hence ok

3.02 Short Time rating of the Cable
Iw
3.03

s
13.2xt

300
13.2*.2

= 50.8

(Fuse Operated)

KA/0.2Sec

2 runs of 1.1kV grade, 3.5C x300 sq.mm, Al conductor, Armoured, XLPE cable is selected
PCH TRANSFORMER TO PMCC

1.00 INPUT DATA

1.01 Feeder Load

2000

KVA

1.02 Voltage rating

VT

0.433

kV

1.03 Length of the cable

60

1.04 AC resistance of the cable at 70C

0.0648 / km

1.05 Reactance of the cable at 50Hz

0.082

1.06 Allowable Voltage Drop

2.5

1.07 Current derating factors

0.65

40 of 284

/ km
%

HZL-BTN-ELE-DS-SY-037

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

2000

=
3 x V

2667

3 x 0.433

Size of 630 Sq.mm single core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

630

1.0

814 A

(Ref : KEI INDUSTRIES LIMITED CATALOG PG.NO. 79)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 814x6x0.65

2.03 current carrying capacity of 630sq.mm,6Run cable

= 3175 A
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

2667
Vdrop

((0.0000648 x 0.8) + (0.000082 x 0.6))

60

6
Vdrop

%Vdrop

2.695

2.695

240

100

1.13

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Short Time rating of the Cable
Iw
3.03

s
13.2xt

630
13.2*1

= 47.7

KA/1Sec

6 runs of 1.1kV grade, 3x1x630 sq.mm+ 3Runs for Neutral ,Al conductor, Armoured, XLPE
cable is selected

PCH TRANSFORMER TO PMCC ( FOR 50% OF LOAD )

1.00 INPUT DATA
1.01 Feeder Load

1000

KVA

1.02 Voltage rating

VT

0.433

kV

1.03 Length of the cable

50

1.04 AC resistance of the cable at 90C

0.129

1.05 Reactance of the cable at 50Hz

0.0705 / km

41 of 284

/ km

HZL-BTN-ELE-DS-SY-037
1.06 Allowable Voltage Drop

2.5

1.07 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

1000

3 x V

1333

3 x 0.433

Size of 300 Sq.mm 3.5 core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

300

1.0

455 A

(Ref : KEI INDUSTRIES LIMITED CATALOG PG.NO. 79)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 455x5x0.65

2.03 current carrying capacity of 300sq.mm,5Run cable

= 1479 A
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

1333
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

50

5
Vdrop

%Vdrop

1.94

1.94

240

100

0.81

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Short Time rating of the Cable
Iw
3.03

s
13.2xt

300
13.2*1

= 22.7

KA/1Sec

(Fuse Operated)

5 runs of 1.1kV grade, 3.5Cx300 sq.mm, Al conductor, Armoured, XLPE cable is selected

42 of 284

HZL-BTN-ELE-DS-SY-037

LT CABLE SIZING CALCULATION

TOTAL POWER FOR +AL2 CABINET (OPERATING BALL MILL)
1.00 INPUT DATA
1.01 Feeder Load

65

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

260

1.04 AC resistance of the cable at 90C

0.409

1.05 Reactance of the cable at 50Hz

0.0724 / km

1.06 Allowable Voltage Drop

/ km
%

2.00 Calculation
2.01 Full load current rating of the Feeder
P

IFL

65 / 0.8

3 x V

3 x 0.415

113

Size of 95 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

95

1.0

221 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 221x1x0.65

2.03 Current carrying capacity of 95 sq.mm1 Run Cable

144 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

113

1
10.889

((0.000409 x 0.8) + (0.0000724 x 0.6))

260

10.889

240

100

4.54

With in the Permissible limit of 5% voltage drop hence ok

3.02 Short Time rating of the Cable
Iw

s
13.2xt

95
13.2*.2

= 16.1

KA/0.2Sec

(Fuse Operated)

3.03 1 run of 1.1kV grade, 3.5C x95sq.mm, Al conductor, Armoured, XLPE cable is selected

42 of 284

HZL-BTN-ELE-DS-SY-037

TOTAL POWER FOR +AL1 CABINET (OPERATING BALL MILL)

1.00 INPUT DATA
1.01 Feeder Load

80

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

260

1.04 AC resistance of the cable at 90C

0.323

1.05 Reactance of the cable at 50Hz

0.0712 / km

1.06 Allowable Voltage Drop

/ km
%

2.00 Calculation
2.01 Full load current rating of the Feeder
P

IFL

80 / 0.8

3 x V

3 x 0.415

139

Size of 120 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

120

1.0

257 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 257x1x0.65

2.03 Current carrying capacity of 120 sq.mm1 Run Cable

167 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

139

1
10.882

((0.000323 x 0.8) + (0.0000712 x 0.6))

260

10.882

240

100

4.54

With in the Permissible limit of 5% voltage drop hence ok

3.02 Short Time rating of the Cable
Iw

s
13.2xt

120
13.2*.2

= 20.3

KA/0.2Sec

(Fuse Operated)

3.03 1 run of 1.1kV grade, 3.5C x120sq.mm, Al conductor, Armoured, XLPE cable is selected

43 of 284

HZL-BTN-ELE-DS-SY-037
TOTAL POWER FOR +AL2 CABINET (OPERATING SAG MILL)
1.00 INPUT DATA
1.01 Feeder Load

60

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

245

1.04 AC resistance of the cable at 90C

0.409

1.05 Reactance of the cable at 50Hz

0.0724 / km

1.06 Allowable Voltage Drop

/ km
%

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

60 / 0.8

3 x V

3 x 0.415

104

Size of 95 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
95

1.0

221 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 221x1x0.65

2.03 Current carrying capacity of 95 sq.mm1 Run Cable

144 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

104

1
9.444

((0.000409 x 0.8) + (0.0000724 x 0.6))

245

9.444

240

100

3.94

With in the Permissible limit of 5% voltage drop hence ok

3.02 Short Time rating of the Cable
Iw

s
13.2xt

95
13.2*.2

= 16.1

KA/0.2Sec

3.03 1 run of 1.1kV grade, 3.5C x95sq.mm, Al conductor, Armoured, XLPE cable is selected

44 of 284

HZL-BTN-ELE-DS-SY-037
TOTAL POWER FOR +AL1 CABINET (OPERATING SAG MILL)
1.00 INPUT DATA
1.01 Feeder Load

80

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

245

1.04 AC resistance of the cable at 90C

0.323

1.05 Reactance of the cable at 50Hz

0.0712 / km

1.06 Allowable Voltage Drop

/ km
%

2.00 Calculation
2.01 Full load current rating of the Feeder
P

IFL

80 / 0.8

3 x V

3 x 0.415

139

Size of 120 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

120

1.0

257 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 257x1x0.65

2.03 Current carrying capacity of 120 sq.mm1 Run Cable

167 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

139

1
10.255

((0.000323 x 0.8) + (0.0000712 x 0.6))

245

10.255

240

100

4.28

With in the Permissible limit of 5% voltage drop hence ok

3.02 Short Time rating of the Cable
Iw

s
13.2xt

120
13.2*.2

= 20.3

KA/0.2Sec

(Fuse Operated)

3.03 1 run of 1.1kV grade, 3.5C x120sq.mm, Al conductor, Armoured, XLPE cable is selected

45 of 284

HZL-BTN-ELE-DS-SY-037
MILL DISCHARGE PUMP - VFD
1.00 INPUT DATA
1.01 Feeder Load

200

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

348

1.04 AC resistance of the cable at 90C

0.161

/ km

1.05 Reactance of the cable at 50Hz

0.071

/ km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

3 x V x

200 / 0.8

0.95x3 x 0.415

366

Size of 240 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
240

1.0

399 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 399x2x0.65

2.03 Current carrying capacity of 240 sq.mm2 Run Cable

519 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos
sin

=
=

0.8 (Assumed)
0.6

Voltage Drop at Normal Running Condition

Vdrop

Vdrop

%Vdrop

366

2
10.915
10.915
240

((0.000161 x 0.8) + (0.000071 x 0.6))

348

V
x

100

4.55

With in the Permissible limit of 5% voltage drop hence ok

3.02 Check for Starting Current
For VFD
= 1098 A
Drop at the time of Starting
Vdrop

Vdrop

1098

( 3 Times the full load current)

((0.000161 x 0.8) + (0.000071 x 0.6))

2
32.746

V
46 of 284

348

HZL-BTN-ELE-DS-SY-037
%Vdrop

32.746

240

100

13.65

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

240

13.2xt

= 40.7

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 2 run of 1.1kV grade, 3.5C x240sq.mm, Al conductor, Armoured, XLPE cable is selected
2 ND STAGE CLASSIFYING CYCLONE FEED PUMPS - VFD
1.00 INPUT DATA
1.01 Feeder Load

110

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

265

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

110 / 0.8

=
3 x V x

201

0.95x3 x 0.415

Size of 185 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
2.02
Cable size
Current Rating at 35C
Temperature 35C
185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 337x1x0.65

2.03 Current carrying capacity of 185 sq.mm1 Run Cable

219 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
=

x (R cos + X sin) x

Where,
cos

sin

0.8 (Assumed)
0.6

Voltage Drop at Normal Running Condition

Vdrop

201
=

((0.00021 x 0.8) + (0.0000718 x 0.6))

1
47 of 284

265

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

11.243

11.243

240

100

4.69

With in the Permissible limit of 5% voltage drop hence ok

3.02 Check for Starting Current
For VFD

603

( 3 Times the full load current)

Drop at the time of Starting

603
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

265

1
Vdrop

%Vdrop

33.73

33.73

240

100

14.06

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

185

13.2xt

= 31.3

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected
ZINC CIRCUIT WATR PUMPS
1.00
1.01
1.02
1.03
1.04
1.05
1.06
1.07
1.08

INPUT DATA
Feeder Load
Voltage rating
Length of the cable
AC resistance of the cable at 90C
Reactance of the cable at 50Hz
Allowable Voltage Drop at normal running cond.
Allowable Voltage Drop at Starting Condition
Current derating factors

P
VT
L
R
X

=
=
=
=
=
=
=
=

75
0.415
230
0.161
0.071
2.5
15
0.65

kW
kV
m
/ km
/ km
%
%

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

75 /0.8
=

3 x V x
2.02

137

3 x 0.415x 0.95

Size of 240 Sq.mm 3.5 core Aluminium cable is selected for checking.
Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
240

1.0

399 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 240 sq.mm1 Run Cable

= 0.65
399*1*0.65

=
=

48 of 284

259 A

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

137
Vdrop

((0.000161 x 0.8) + (0.000071 x 0.6))

230

3.02

Vdrop

%Vdrop

5.401
5.401

240

100

2.26

With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

822

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

822

((0.000161 x 0.8) + (0.000071 x 0.6))

230

32.405
32.405

240

100

13.51

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

240

13.2xt

13.2*.2

= 40.7

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x240sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner I Concentrate Froth Pump
1.00
1.01
1.02
1.03
1.04
1.05
1.06
1.07
1.08
2.00
2.01

INPUT DATA
Feeder Load
Voltage rating
Length of the cable
AC resistance of the cable at 90C
Reactance of the cable at 50Hz
Allowable Voltage Drop at normal running cond.
Allowable Voltage Drop at Starting Condition
Current derating factors
Calculation
Full load current rating of the Feeder
IFL

P
3 x V x

75 / 0.8
0.95x3 x 0.415

P
VT
L
R
X

=
=
=
=
=
=
=
=

137

75
0.415
276
0.129
0.0705
2.5
15
0.65

Size of 300 Sq.mm 3.5core Aluminium cable is selected for checking.

49 of 284

kW
kV
m
/ km
/ km
%
%

HZL-BTN-ELE-DS-SY-037
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

300

1.0

455 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 300 sq.mm1 Run Cable
3.00 Check for voltage drop

455*1*0.65

3.01 Voltage drop

IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

137
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

276

1
Vdrop

%Vdrop

5.502
5.502
240

V
x

100

2.3

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage

822

( 6 Times the full load current)

Drop at the time of Starting

822
Vdrop

((0.000129 x 0.8) + (0.0000705 x 276))

276

1
Vdrop

%Vdrop

33.01
33.01
240

V
x

100

13.76

With in the limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
300
s
Iw
=
= 50.8 KA/0.2Sec
=
(Fuse Operated)
13.2xt
13.2*.2
3.04 1 run of 1.1kV grade, 3.5C x300sq.mm, Al conductor, Armoured, XLPE cable is selected
INSTRUMENT AIR COMPRESSOR 1/COMPRESSOR 2
1.00 INPUT DATA
1.01 Feeder Load
1.04 Voltage rating

P
VT

=
=

90
0.415

1.03 Length of the cable

329

50 of 284

kW
kV
m

HZL-BTN-ELE-DS-SY-037
1.04 AC resistance of the cable at 90C

1.05 Reactance of the cable at 50Hz

0.21

/ km

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

P
3 x V x

90 / 0.8

3 x 0.415x 0.95

165

Size of 185 sq.mm 3.5 core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 185 sq.mm 2Run cable

337*2*0.65

=
=

438 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
0.8 (Assumed)
cos
=
sin
=
0.6
Voltage Drop at Normal Running Condition
Vdrop

Vdrop

%Vdrop

165

2
5.729
5.729
240

((0.00021 x 0.8) + (0.0000718 x 0.6))

329

V
x

100

2.39

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrel Cage
=
Drop at the time of Starting

990

( 6 Times the full load current)

990
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

2
Vdrop

%Vdrop

34.375
34.375
240

V
x

100

14.33

51 of 284

329

HZL-BTN-ELE-DS-SY-037
With in the Permissible limit of 15% voltage drop hence ok
It is to be noted that motor has been selected to start upto 80% of rated voltage

3.03 Short Time rating of the Cable

Iw
3.04

185

13.2xt

= 31.3

13.2*.2

(Fuse Operated)

KA/0.2Sec

2 runs of 1.1kV grade, 3.5C x185 sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Concentrate Storage tank agitator 2

1.00 INPUT DATA

1.01 Feeder Load

55

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

350

1.04 AC resistance of the cable at 90C

0.129

1.05 Reactance of the cable at 50Hz

0.0705 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

55 /0.8

=
3 x V x

101

3 x 0.415x 0.95

Size of 300 Sq.mm 3.5 core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

300

1.0

455 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 300 sq.mm1 Run Cable

455*1*0.65

=
=

296 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos
sin

=
=

0.8 (Assumed)
0.6

Voltage Drop at Normal Running Condition

101
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

1
52 of 284

350

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

5.143
5.143

240

100

2.15

With in the Permissible limit of 2.5% voltage drop hence ok

3.02

Check for Starting Current

DOL or Squirrel Cage

606

( 6 Times the full load current)

Drop at the time of Starting

606
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

350

1
Vdrop

%Vdrop

30.861
30.861

240

100

12.86

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

3.03 Short Time rating of the Cable

Iw

300

13.2xt

= 50.8

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x300sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Concentrate Filter feed pumps 2 (VFD)
1.00 INPUT DATA
1.01 Feeder Load

55

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

335

1.04 AC resistance of the cable at 90C

0.323

1.05 Reactance of the cable at 50Hz

0.0712 / km

/ km

1.06 Allowable Voltage Drop

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

55 / 0.8

3 x V x
2.02

101

3 x 0.415x 0.95

Size of 120 Sq.mm 3.5 core Aluminium cable is selected for checking.
Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
120

1.0

257 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables
= 0.86
Reduction Factor

0.9

Factor for Non linear loads

0.8

53 of 284

HZL-BTN-ELE-DS-SY-037
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 120 sq.mm1 Run Cable

257*1*0.65

167 A

=
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

101
Vdrop

((0.000323 x 0.8) + (0.0000712 x 0.6))

335

1
Vdrop

%Vdrop

10.188

10.188

240

100

4.25

With in Permissible voltage drop is 5% on 240V basis hence ok

3.02

Check for Starting Current

For VFD

303

((0.000323 x 0.8) + (0.0000712 x 0.0712)) x

( 3 Times the full load current)

Drop at the time of Starting

303
Vdrop

335

1
Vdrop

%Vdrop

30.565

30.565

240

100

12.74

With in the Permissible limit of 15%voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

120
13.2*.2

= 20.3

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x120sq.mm, Al conductor, Armoured, XLPE cable is selected
PLANT AIR /FILTER AIR COMPRESSOR 3/COMPRESSOR 4
1.00 INPUT DATA
1.01 Feeder Load

55

kW

1.04 Voltage rating

VT

0.415

kV

1.03 Length of the cable

327

1.04 AC resistance of the cable at 90C

0.161

/ km

1.05 Reactance of the cable at 50Hz

0.071

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

54 of 284

HZL-BTN-ELE-DS-SY-037
1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
55 / 0.8

P
IFL

=
3 x V x

101

3 x 0.415x 0.95

Size of 240 sq.mm 3.5 core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

240

1.0

399 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 240 sq.mm 1Run cable

399*1*0.65

=
=

259 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

Vdrop

Vdrop

%Vdrop

101

1
5.661
5.661
240

((0.000161 x 0.8) + (0.000071 x 0.6))

327

V
x

100

2.36

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage

606

( 6 Times the full load current)

Drop at the time of Starting

606
Vdrop

((0.000161 x 0.8) + (0.000071 x 0.6))

327

1
Vdrop

33.965

%Vdrop

33.965
240

V
x

100

14.16

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

55 of 284

HZL-BTN-ELE-DS-SY-037
3.03 Short Time rating of the Cable
Iw
3.04

240

13.2xt

= 40.7

13.2*.2

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 3.5C x240 sq.mm, Al conductor, Armoured, XLPE cable is selected
PROCESS PLANT GLAND SEAL WATER PUMP 1/PUMP 2

1.00 INPUT DATA

1.01 Feeder Load

55

kW

1.04 Voltage rating

VT

0.415

kV

1.03 Length of the cable

354

1.04 AC resistance of the cable at 90C

0.129

1.05 Reactance of the cable at 50Hz

0.0705 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

55 / 0.8

101

3 x 0.415x 0.95

3 x V x

Size of 300 sq.mm 3.5 core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

300

1.0

455 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 300 sq.mm 1Run cable

455*1*0.65

=
=

296 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

Where,
cos
sin

=
=

0.8 (Assumed)
0.6

Voltage Drop at Normal Running Condition

Vdrop

Vdrop

%Vdrop

101

1
V

5.202
5.202
240

((0.000129 x 0.8) + (0.0000705 x 0.6))

100

=
56 of 284

2.17

354

HZL-BTN-ELE-DS-SY-037
With in the Permissible limit of 2.5% voltage drop hence ok
3.02 Check for Starting Current
DOL or Squirrelcage

606

( 6 Times the full load current)

Drop at the time of Starting

606
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

354

1
Vdrop

%Vdrop

31.213

31.213

240

100

13.01

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

3.03 Short Time rating of the Cable

Iw
3.04

s
13.2xt

300

= 50.8

13.2*.2

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 3.5C x300 sq.mm, Al conductor, Armoured, XLPE cable is selected
COOLING WATER PUMP

1.00 INPUT DATA

1.01 Feeder Load

55

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

287

1.04 AC resistance of the cable at 90C

0.161

/ km

1.05 Reactance of the cable at 50Hz

0.071

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

=
3 x V x

2.02

55 / 0.8
=

101

3 x 0.415x 0.95

Size of 240 Sq.mm 3.5 core Aluminium cable is selected for checking.
Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
240

1.0

399 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 240sq.mm,1Run cable

= 0.65
= 399x1x0.65
=

57 of 284

259 A

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

101
Vdrop

((0.000161 x 0.8) + (0.000071 x 0.6))

287

1
Vdrop

%Vdrop

4.968
4.968

240

100

2.07

With in the permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage

606

( 6 Times the full load current)

Drop at the time of Starting

606
Vdrop

((0.000161 x 0.8) + (0.000071 x 0.6))

287

1
Vdrop

%Vdrop

29.81
29.81
240

V
x

100

12.43

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

3.03 Short Time rating of the Cable

Iw
3.04

s
13.2xt

240
13.2*.2

= 40.7

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 3.5C x240 sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner IV Cell 1

1.00 INPUT DATA

1.01 Feeder Load

45

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

210

1.04 AC resistance of the cable at 90C

0.323

1.05 Reactance of the cable at 50Hz

0.0712 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

58 of 284

HZL-BTN-ELE-DS-SY-037
2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

45 / 0.8

3 x V x

0.95x3 x 0.415

82

Size of 120 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
120

1.0

257 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 120 sq.mm1 Run Cable

257*1*0.65

=
=

167 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL

Vdrop

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

Voltage Drop at Normal Running Condition

82

Vdrop

Vdrop

%Vdrop

((0.000323 x 0.8) + (0.0000712 x 0.6))

210

1
V

5.185
5.185

240

100

2.17

With in the Permissible limit of 2.5% voltege drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage

492

( 6 Times the full load current)

Drop at the time of Starting

492
Vdrop

Vdrop

((0.000323 x 0.8) + (0.0000712 x 0.6))

210

31.112

31.112
x 100
=
12.97
%
240
With in the Permissible limit of 15% voltage drop hence ok

%Vdrop

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

120
13.2*.2

= 20.3

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x120sq.mm, Al conductor, Armoured, XLPE cable is selected
59 of 284

HZL-BTN-ELE-DS-SY-037

LT CABLE SIZING CALCULATION

Pb Rougher cell 1
1.00 INPUT DATA
1.01 Feeder Load

75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

328

1.04 AC resistance of the cable at 90C

0.264

1.05 Reactance of the cable at 50Hz

0.0716 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
75 / 0.8

P
IFL

3 x V x
2.02

130

0.95x3 x 0.415

Size of 150 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
150

1.0

292 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 292x2x0.65

2.03 Current carrying capacity of sq.mm2 Run Cable

380 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

130
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

100

2
Vdrop

%Vdrop

5.419
5.419
240

V
x

2.26

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

780

( 6 Times the full load current)

60 of 284

328

HZL-BTN-ELE-DS-SY-037
Drop at the time of Starting
780
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

328

2
Vdrop

%Vdrop

32.512

32.512

240

100

13.55

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

150

13.2xt

13.2*.2

KA/0.2Sec

= 25.4

(Fuse Operated)

3.04 2 run of 1.1kV grade, 3.5C x150sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Rougher cell 2
1.00 INPUT DATA
1.01 Feeder Load

75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

323

1.04 AC resistance of the cable at 90C

0.264

1.05 Reactance of the cable at 50Hz

0.0716 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

3 x V x

75 / 0.8
0.95x3 x 0.415

130

Size of 150 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
150

1.0

292 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables
= 0.86
Reduction Factor
= 0.9
Factor for Non linear loads
= 0.8
Total factor to be applied for arriving the capacity = 0.65
= 292x2x0.65
2.03 Current carrying capacity of sq.mm2 Run Cable
= 380 A
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
61 of 284

HZL-BTN-ELE-DS-SY-037
130
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

323

2
Vdrop

%Vdrop

5.336
5.336

240

100

2.23

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

780

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

780

2
32.017

((0.000264 x 0.8) + (0.0000716 x 0.6))

323

32.017

240

100

13.35

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

150

13.2xt

= 25.4

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 2 run of 1.1kV grade, 3.5C x150sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Rougher cell 3
1.00 INPUT DATA
1.01 Feeder Load

75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

318

1.04 AC resistance of the cable at 90C

0.264

1.05 Reactance of the cable at 50Hz

0.0716 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

P
3 x V x

75 / 0.8

0.95*3 x 0.415

137

Size of 150 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

150

1.0

292 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86
62 of 284

HZL-BTN-ELE-DS-SY-037
Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 292x2x0.65

2.03 Current carrying capacity of sq.mm2 Run Cable

380 A

=
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

137
Vdrop

318

((0.000264 x 0.8) + (0.0000716 x 0.6))

2
Vdrop

%Vdrop

5.536

5.536

240

100

2.31

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

822

( 6 Times the full load current)

Drop at the time of Starting

822
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

318

2
Vdrop

%Vdrop

33.218

33.218

240

100

13.85

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

150
13.2*.2

= 25.4

(Fuse Operated)

KA/0.2Sec

3.04 2 run of 1.1kV grade, 3.5C x150sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Scavenger cell 4
1.00 INPUT DATA
1.01 Feeder Load

75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

312

1.04 AC resistance of the cable at 90C

0.264

1.05 Reactance of the cable at 50Hz

0.0716 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

63 of 284

HZL-BTN-ELE-DS-SY-037
1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

75 / 0.8

3 x V x

137

0.95*3 x 0.415

Size of 150 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

150

1.0

292 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 292x2x0.65

2.03 Current carrying capacity of sq.mm Run Cable

380 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

137
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

312

2
Vdrop

%Vdrop

5.432
5.432
240

V
x

100

2.27

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

822

( 6 Times the full load current)

Drop at the time of Starting

822
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

312

2
Vdrop

%Vdrop

32.591
32.591
240

V
x

100

13.58

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
64 of 284

HZL-BTN-ELE-DS-SY-037
3.03 Short Time rating of the Cable
Iw

150

13.2xt

= 25.4

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 2 run of 1.1kV grade, 3.5C x150sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Scavenger cell 5
1.00 INPUT DATA
1.01 Feeder Load

75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

307

1.04 AC resistance of the cable at 90C

0.264

1.05 Reactance of the cable at 50Hz

0.0716 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

75 / 0.8

3 x V x

137

0.95*3 x 0.415

Size of 150 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

150

1.0

292 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 292x2x0.65

2.03 Current carrying capacity of sq.mm2 Run Cable

380 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

137
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

2
Vdrop

5.345

V
65 of 284

307

HZL-BTN-ELE-DS-SY-037
%Vdrop

5.345

240

100

2.23

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

822

( 6 Times the full load current)

Drop at the time of Starting

822
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

307

2
Vdrop

%Vdrop

32.069

32.069

240

100

13.37

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

150

13.2xt

= 25.4

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 2 run of 1.1kV grade, 3.5C x150sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Scavenger cell 6
1.00 INPUT DATA
1.01 Feeder Load

75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

302

1.04 AC resistance of the cable at 90C

0.264

1.05 Reactance of the cable at 50Hz

0.0716 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

75 / 0.8

=
3 x V x

137

0.95*3 x 0.415

Size of 150 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

150

1.0

292 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of sq.mm2 Run Cable

= 0.65
= 292x2x0.65
=

66 of 284

380 A

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos
sin

=
=

0.8 (Assumed)
0.6

137
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

302

2
Vdrop

%Vdrop

5.258
5.258
240

V
x

100

2.2

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor
= 822 A ( 6 Times the full load current)
Drop at the time of Starting
822
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

302

2
Vdrop

%Vdrop

31.547
31.547
240

100

13.15

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
150
s
Iw
=
= 25.4 KA/0.2Sec
=
(Fuse Operated)
13.2xt
13.2*.2
3.04 2 run of 1.1kV grade, 3.5C x150sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Scavenger Cell 7
1.00 INPUT DATA
1.01 Feeder Load

75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

295

1.04 AC resistance of the cable at 90C

0.129

1.05 Reactance of the cable at 50Hz

0.0705 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

75 / 0.8
=

3 x V x

=
3 x 0.415x 0.95
67 of 284

137

HZL-BTN-ELE-DS-SY-037

Size of 300 Sq.mm 3.5 core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

300

1.0

455 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

455*1*0.65

2.03 Current carrying capacity of 185 sq.mm,1 Run Cable =

=

296 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

137

((0.000129 x 0.8) + (0.0000705 x 0.6))

295

5.88
5.88

240

100

2.45

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

822

( 6 Times the full load current)

Drop at the time of Starting

822
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

295

1
Vdrop

%Vdrop

35.282

35.282

240

100

14.71

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

300
13.2*.2

= 50.8

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x300sq.mm, Al conductor, Armoured, XLPE cable is selected

68 of 284

HZL-BTN-ELE-DS-SY-037
Zn FILTER MAINFOLD MAINFOLD WASH WATER PUMPS
1.00 INPUT DATA
1.01 Feeder Load

75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

340

1.04 AC resistance of the cable at 90C

0.264

1.05 Reactance of the cable at 50Hz

0.0716 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

75 / 0.8

3 x V

2.02

137

3 x 0.415x 0.95

Size of 150 Sq.mm 3.5 core Aluminium cable is selected for checking.
Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
150

1.0

292 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 150 sq.mm2 Run Cable

292*2*0.65

=
=

380 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

137
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

2
Vdrop

%Vdrop

5.919
5.919
240

V
x

100

2.47

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

822

( 6 Times the full load current)

69 of 284

340

HZL-BTN-ELE-DS-SY-037
Drop at the time of Starting
822
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

340

2
Vdrop

%Vdrop

35.516

35.516

100

240

14.8

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

150

13.2xt

= 25.4

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 2 run of 1.1kV grade, 3.5C x150sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Scavenger Tails pumps (VFD)
1.00 INPUT DATA
1.01 Feeder Load

75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

347

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

75 / 0.8

2.02

=
3 x V x

137

0.95*3 x 0.415

Size of 185 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 337x1x0.65

2.03 Current carrying capacity of sq.mm1 Run Cable

=
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL
n

x (R cos + X sin) x

70 of 284

219 A

HZL-BTN-ELE-DS-SY-037
Where,
cos

0.8 (Assumed)

sin

0.6

137
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

347

1
Vdrop

%Vdrop

10.035

10.035

240

100

4.19

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
For VFD

411

( 3 Times the full load current)

Drop at the time of Starting

411
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

347

1
Vdrop

%Vdrop

30.104

30.104

240

100

12.55

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

185

13.2xt

13.2*.2

= 31.3

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner IV Cell 2
1.00 INPUT DATA
1.01 Feeder Load

45

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

215

1.04 AC resistance of the cable at 90C

0.323

1.05 Reactance of the cable at 50Hz

0.0712 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

82

2.00 Calculation
2.01 Full load current rating of the Feeder
45 / 0.8

P
IFL

=
3 x V x

=
0.95x3 x 0.415

Size of 120 Sq.mm 3.5 core Aluminium cable is selected for checking.

71 of 284

HZL-BTN-ELE-DS-SY-037
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

120

1.0

257 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 120 sq.mm1 Run Cable

257*1*0.65

167 A

=
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL
x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

82

1
5.309

((0.000323 x 0.8) + (0.0000712 x 0.6))

215

5.309

240

100

2.22

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

492

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

492

1
31.852
31.852
240

((0.000323 x 0.8) + (0.0000712 x 0.6))

215

V
x

100

13.28

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
120
s
Iw
= 20.3 KA/0.2Sec
(Fuse Operated)
=
=
13.2*.2
13.2xt
3.04 1 run of 1.1kV grade, 3.5C x120sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner IV Concentrate Froth Pump
1.00 INPUT DATA
1.01 Feeder Load

45

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

255

1.04 AC resistance of the cable at 90C

0.264

72 of 284

/ km

HZL-BTN-ELE-DS-SY-037
1.05 Reactance of the cable at 50Hz

0.0716 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

82

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

45 / 0.8

3 x V

0.95*3 x 0.415

Size of 150 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

150

1.0

292 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 292x1x0.65

2.03 Current carrying capacity of sq.mm1 Run Cable

190 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

82
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

255

1
Vdrop

%Vdrop

5.314
5.314
240

V
x

100

2.22

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

492

( 6 Times the full load current)

Drop at the time of Starting

492
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

1
Vdrop

%Vdrop

31.887
31.887
240

V
x

100

13.29

73 of 284

255

HZL-BTN-ELE-DS-SY-037
With in the Permissible limit of 15% voltage drop hence ok
It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

150

13.2xt

KA/0.2Sec

= 25.4

13.2*.2

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x150sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner III Cell 3
1.00 INPUT DATA
1.01 Feeder Load

45

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

220

1.04 AC resistance of the cable at 90C

0.323

1.05 Reactance of the cable at 50Hz

0.0712 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

82

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

45 / 0.8

3 x V x
2.02

0.95*3 x 0.415

Size of 120 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Current Rating at 35C
Cable size
Temperature 35C
120

1.0

257 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 120 sq.mm1 Run Cable

257*1*0.65

=
=

167 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

82

1
5.432
5.432
240

((0.000323 x 0.8) + (0.0000712 x 0.6))

V
x

100

=
74 of 284

2.27

220

HZL-BTN-ELE-DS-SY-037
With in the Permissible limit of 2.5% voltage drop hence ok
3.02 Check for Starting Current
DOL or Squirrelcage Motor

492

( 6 Times the full load current)

Drop at the time of Starting

492
Vdrop

((0.000323 x 0.8) + (0.0000712 x 0.6))

220

1
Vdrop

%Vdrop

32.593

32.593

240

100

13.59

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

120

13.2xt

= 20.3

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x120sq.mm, Al conductor, Armoured, XLPE cable is selected

Zn Cleaner III Cell 4

1.00 INPUT DATA
1.01 Feeder Load

45

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

225

1.04 AC resistance of the cable at 90C

0.323

1.05 Reactance of the cable at 50Hz

0.0712 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

82

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

45 / 0.8

=
3 x V x

=
0.95*3 x 0.415

Size of 120 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

120

1.0

257 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 120 sq.mm1 Run Cable

= 0.65
257*1*0.65

=
=

75 of 284

167 A

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
IFL

Vdrop

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

82

((0.000323 x 0.8) + (0.0000712 x 0.6))

1
4.861

225

4.861

240

100

2.03

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

492

( 6 Times the full load current)

Drop at the time of Starting

492
Vdrop

((0.000323 x 0.8) + (0.0000712 x 0.6))

225

1
Vdrop

%Vdrop

33.334

33.334

240

100

13.89

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

120

13.2xt

13.2*.2

= 20.3

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x120sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner III Cell 5
1.00 INPUT DATA
1.01 Feeder Load

45

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

230

1.04 AC resistance of the cable at 90C

0.323

1.05 Reactance of the cable at 50Hz

0.0712 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

82

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

45 / 0.8
=

3 x V x

=
0.95*3 x 0.415
76 of 284

HZL-BTN-ELE-DS-SY-037
Size of 120 Sq.mm 3.5core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

120

1.0

257 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 120 sq.mm1 Run Cable

257*1*0.65

=
=

167 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL

Vdrop

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

82

Vdrop

Vdrop

%Vdrop

((0.000323 x 0.8) + (0.0000712 x 0.6))

230

1
5.679

5.679

240

100

2.37

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

492

( 6 Times the full load current)

Drop at the time of Starting

492
Vdrop

((0.000323 x 0.8) + (0.0000712 x 0.6))

230

1
Vdrop

%Vdrop

34.075

34.075

240

100

14.2

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

120
13.2*.2

= 20.3

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x120sq.mm, Al conductor, Armoured, XLPE cable is selected

77 of 284

HZL-BTN-ELE-DS-SY-037
Zn Cleaner II Cell 6
1.00 INPUT DATA
1.01 Feeder Load

45

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

235

1.04 AC resistance of the cable at 90C

0.323

1.05 Reactance of the cable at 50Hz

0.0712 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

82

2.00 Calculation
2.01 Full load current rating of the Feeder
45 / 0.8

P
IFL

3 x V x

0.95*3 x 0.415

Size of 120 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

120

1.0

257 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 120 sq.mm1 Run Cable

257*1*0.65

=
=

167 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
=

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

82

1
5.803
5.803
240

((0.000323 x 0.8) + (0.0000712 x 0.6))

235

V
x

100

2.42

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor
= 492 A ( 6 Times the full load current)
Drop at the time of Starting
492
Vdrop

((0.000323 x 0.8) + (0.0000712 x 0.6))

1
78 of 284

235

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

34.815

34.815

240

100

14.51

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

120

13.2xt

= 20.3

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x120sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner II Cell 7
1.00 INPUT DATA
1.01 Feeder Load

45

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

240

1.04 AC resistance of the cable at 90C

0.323

1.05 Reactance of the cable at 50Hz

0.0712 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

82

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

3 x V x

45 / 0.8

0.95*3 x 0.415

Size of 120 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

120

1.0

257 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 120 sq.mm1 Run Cable

257*1*0.65

=
=

167 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

cos

0.8 (Assumed)

sin

0.6

82
1

((0.000323 x 0.8) + (0.0000712 x 0.6))

79 of 284

240

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

5.926

5.926

240

100

2.47

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

492

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

492

((0.000323 x 0.8) + (0.0000712 x 0.6))

1
35.556

240

35.556

240

100

14.82

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

120

13.2xt

= 20.3

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x120sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner II Cell 8
1.00 INPUT DATA
1.01 Feeder Load

45

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

245

1.04 AC resistance of the cable at 90C

0.264

1.05 Reactance of the cable at 50Hz

0.0716 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

82

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

45 / 0.8

3 x V x
2.02

=
0.95*3 x 0.415

Size of 150 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
150

1.0

292 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 150 sq.mm1 Run Cable

= 0.65
292*1*0.65

=
=

80 of 284

190 A

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

82

1
5.106

((0.000264 x 0.8) + (0.0000716 x 0.6))

245

5.106

240

100

2.13

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

492

( 6 Times the full load current)

Drop at the time of Starting

492
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

245

1
Vdrop

%Vdrop

30.636

30.636

240

12.77

100

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

150

13.2xt

13.2*.2

KA/0.2Sec

= 25.4

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x150sq.mm, Al conductor, Armoured, XLPE cable is selected
Electric overhead travelling crane (Area D)
1.00 INPUT DATA
1.01 Feeder Load

9.15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

330

1.04 AC resistance of the cable at 90C

1.11

/ km

1.05 Reactance of the cable at 50Hz

0.0783 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

17

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

P
3 x V x

9.15 / 0.8
0.95x3 x 0.415
81 of 284

HZL-BTN-ELE-DS-SY-037
Size of 35 Sq.mm 3.5core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 117x1x0.65

2.03 Current carrying capacity of sq.mm1 Run Cable

76

3.00 Check for voltage drop

3.01 Voltage drop
IFL

Vdrop

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

17
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

330

1
Vdrop

%Vdrop

5.245
5.245

240

100

2.19

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

102

( 6 Times the full load current)

Drop at the time of Starting

102
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

330

1
Vdrop

%Vdrop

31.471

31.471

240

100

13.12

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

35
13.2*.2

= 5.93

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected

82 of 284

HZL-BTN-ELE-DS-SY-037
EOT Crane (Area - E)
1.00 INPUT DATA
1.01 Feeder Load

5.25

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

300

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

5.25 / 0.8

3 x V x

3 x 0.415x 0.95

Size of 25 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 25 sq.mm1 Run Cable

96*1*0.65

=
=

62

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

10

1
3.817
3.817
240

((0.00153 x 0.8) + (0.0000805 x 0.6))

300

V
x

100

1.6

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

60

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

60
1

((0.00153 x 0.8) + (0.0000805 x 0.6))

83 of 284

300

HZL-BTN-ELE-DS-SY-037

Vdrop

%Vdrop

22.901
22.901

240

100

9.55

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

25
13.2*.2

= 4.23

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected

84 of 284

HZL-BTN-ELE-DS-SY-037

LT CABLE SIZING CALCULATION

Zn SCAVENGER TAILS PUMPS - VFD
1.00 INPUT DATA
1.01 Feeder Load

110

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

304

1.04 AC resistance of the cable at 90C

0.161

/ km

1.05 Reactance of the cable at 50Hz

0.071

/ km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

110 / 0.8

3 x V

0.95x3 x 0.415

201

Size of 240 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

240

1.0

399 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 240 sq.mm1 Run Cable

399*1*0.65

=
=

259 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

201
Vdrop

((0.000161 x 0.8) + (0.000071 x 0.6))

1
Vdrop

%Vdrop

10.473
10.473
240

V
x

100

4.37

With in the Permissible limit of 5% voltage drop hence ok

3.02 Check for Starting Current
For VFD

603

( 3 Times the full load current)

85 of 284

304

HZL-BTN-ELE-DS-SY-037
Drop at the time of Starting
603
Vdrop

((0.000161 x 0.8) + (0.000071 x 0.6))

304

1
Vdrop

%Vdrop

31.42

31.42

240

100

13.1

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

240

13.2xt

13.2*.2

40.7

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x240sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn REGRIND MILL DISCHARGE PUMPS - VFD
1.00 INPUT DATA
1.01 Feeder Load

110

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

289

1.04 AC resistance of the cable at 90C

0.161

/ km

1.05 Reactance of the cable at 50Hz

0.071

/ km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

3 x V x

110 / 0.8

0.95x3 x 0.415

201

Size of 240 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

240

1.0

399 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 240 sq.mm1 Run Cable

399*1*0.65

=
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
=

(R cos + X sin)

Where,
86 of 284

259 A

HZL-BTN-ELE-DS-SY-037
cos

0.8 (Assumed)

sin

0.6

201

Vdrop

Vdrop

%Vdrop

((0.000161 x 0.8) + (0.000071 x 0.6))

289

1
V

9.956
9.956

240

100

4.15

With in the Permissible limit of 5% voltage drop hence ok

3.02 Check for Starting Current
For VFD

603

( 3 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

603

1
29.869

((0.000161 x 0.8) + (0.000071 x 0.6))

289

29.869

240

100

12.45

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

240

13.2xt

13.2*.2

KA/0.2Sec

40.7

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x240sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Rougher cell 1
1.00 INPUT DATA
1.01 Feeder Load

90

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

285

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

P
3 x V x

90 / 0.8
0.95x3 x 0.415

165

Size of 185 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

87 of 284

HZL-BTN-ELE-DS-SY-037
Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 185 sq.mm2 Run Cable

= 337*2*0.65
438 A

=
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

165

Vdrop

Vdrop

%Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

285

2
V

4.963
4.963

240

100

2.07

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

990

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

990

2
29.778

((0.00021 x 0.8) + (0.0000718 x 0.6))

285

29.778

240

100

12.41

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

185
13.2*.2

KA/0.2Sec

31.3

(Fuse Operated)

3.04 2 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Rougher cell 2
1.00 INPUT DATA
1.01 Feeder Load

90

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

290

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
88 of 284

HZL-BTN-ELE-DS-SY-037
2.01 Full load current rating of the Feeder
IFL

90 / 0.8

3 x V x

0.95x3 x 0.415

165

Size of 185 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 185 sq.mm2 Run Cable

337*2*0.65

=
=

438 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

165

Vdrop

%Vdrop

%Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

290

2
2

240

100

0.84

0.84

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

990

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

990

2
30.301

((0.00021 x 0.8) + (0.0000718 x 0.6))

290

30.301

240

100

12.63

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

185
13.2*.2

31.3

KA/0.2Sec

(Fuse Operated)

3.04 2 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Rougher cell 3
89 of 284

HZL-BTN-ELE-DS-SY-037
1.00 INPUT DATA
1.01 Feeder Load

90

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

295

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
90 / 0.8

P
IFL

165

0.95x3 x 0.415

3 x V x

Size of 185 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
2.02
Current Rating at 35C
Cable size
Temperature 35C
185

337 A

1.0

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 185 sq.mm2 Run Cable

= 337*2*0.65
=

438 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

165

5.137
5.137
240

((0.00021 x 0.8) + (0.0000718 x 0.6))

295

V
x

100

2.15

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

990

( 6 Times the full load current)

Drop at the time of Starting

990
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

2
Vdrop

30.823

V
90 of 284

295

HZL-BTN-ELE-DS-SY-037
%Vdrop

30.823

240

100

12.85

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

185

13.2xt

13.2*.2

31.3

KA/0.2Sec

(Fuse Operated)

3.04 2 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn scavenger cell 4
1.00 INPUT DATA
1.01 Feeder Load

90

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

300

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

90 / 0.8

=
3 x V x

2.02

165

0.95x3 x 0.415

Size of 185 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Current Rating at 35C
Cable size
Temperature 35C
185

337 A

1.0

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 185 sq.mm2 Run Cable

337*2*0.65

=
=

438 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos
sin

=
=

0.8 (Assumed)
0.6

165
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

2
91 of 284

300

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

5.224

5.224

240

100

2.18

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

990

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

990

240

300

31.345
31.345

((0.00021 x 0.8) + (0.0000718 x 0.6))

100

13.07

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
185
s
Iw
=
= 31.3 KA/0.2Sec
=
(Fuse Operated)
13.2xt
13.2*.2
3.04 2 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Concentrate Filter feed pumps 1 - VFD
1.00 INPUT DATA
1.01 Feeder Load

55

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

330

1.04 AC resistance of the cable at 90C

0.323

1.05 Reactance of the cable at 50Hz

0.0712 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

55 / 0.8

=
3 x V x

101

3 x 0.415x 0.95

Size of 120 Sq.mm 3.5 core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

120

1.0

257 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 120 sq.mm1 Run Cable
92 of 284

= 0.65
=

257*1*0.65

HZL-BTN-ELE-DS-SY-037
167 A

=
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

101
Vdrop

((0.000323 x 0.8) + (0.0000712 x 0.6))

330

1
Vdrop

%Vdrop

10.036
10.036
240

V
x

100

4.19

With in the Permissible limit of 5% voltage drop hence ok

3.02 Check for Starting Current
For VFD
= 303 A ( 3 Times the full load current)
Drop at the time of Starting
Vdrop

Vdrop

%Vdrop

303

1
30.109
30.109
240

((0.000323 x 0.8) + (0.0000712 x 0.6))

330

V
x

100

12.55

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
120
s
Iw
=
= 20.3 KA/0.2Sec
(Fuse Operated)
=
13.2*.2
13.2xt
3.04 1 run of 1.1kV grade, 3.5C x120sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner II Concentrate Froth Pump
1.00
1.01
1.02
1.03
1.04
1.05
1.06
1.07
1.08
2.00

INPUT DATA
Feeder Load
Voltage rating
Length of the cable
AC resistance of the cable at 90C
Reactance of the cable at 50Hz
Allowable Voltage Drop at normal running cond.
Allowable Voltage Drop at Starting Condition
Current derating factors
Calculation

P
VT
L
R
X

=
=
=
=
=
=
=
=

45
0.415
268
0.264
0.0716
2.5
15
0.65

2.01 Full load current rating of the Feeder

P
IFL

45 / 0.8
=

3 x V x

82

0.95*3 x 0.415

Size of 150 Sq.mm 3.5core Aluminium cable is selected for checking.

93 of 284

kW
kV
m
/ km
/ km
%
%

HZL-BTN-ELE-DS-SY-037
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

150

1.0

292 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 150 sq.mm1 Run Cable

292*1*0.65

190 A

=
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

82

1
5.585

((0.000264 x 0.8) + (0.0000716 x 0.6))

268

5.585

240

100

2.33

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

492

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

492

1
33.513

((0.000264 x 0.8) + (0.0000716 x 0.6))

268

33.513

240

100

13.97

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

150
13.2*.2

25.4

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x150sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner tail pump - VFD
1.00 INPUT DATA
1.01 Feeder Load

45

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

280

1.04 AC resistance of the cable at 90C

0.565

94 of 284

/ km

HZL-BTN-ELE-DS-SY-037
1.05 Reactance of the cable at 50Hz

0.074

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

82

/ km

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

45 / 0.8

3 x V

0.95x3 x 0.415

Size of 70 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02
Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

179*1*0.65

=
=

116 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

82

240

280

11.397
11.397

((0.000565 x 0.8) + (0.000074 x 0.6))

100

4.75

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
For VFD

246

( 3 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

246

1
34.192
34.192
240

((0.000565 x 0.8) + (0.000074 x 0.6))

280

V
x

100

14.25

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
95 of 284

HZL-BTN-ELE-DS-SY-037
70
s
=
= 11.9 KA/0.2Sec
(Fuse Operated)
13.2xt
13.2*.2
3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
Iw

Zn Concentrate filter 1 Hydrralic unit

1.00 INPUT DATA
1.01 Feeder Load

45

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

313

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

82

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

45 / 0.8

=
3 x V

3 x 0.415x 0.95

Size of 185 Sq.mm 3.5 core Aluminium cable is selected for checking.
Rating factor for Ambient
2.02
Cable size
Current Rating at 35C
Temperature 35C
185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 185 sq.mm1 Run Cable

337*1*0.65

=
=

219 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

82

1
5.418
5.418
240

((0.00021 x 0.8) + (0.0000718 x 0.6))

V
x

100

2.26

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

492

( 6 Times the full load current)

96 of 284

313

HZL-BTN-ELE-DS-SY-037
Drop at the time of Starting
Vdrop

Vdrop

%Vdrop

492

1
32.505

((0.00021 x 0.8) + (0.0000718 x 0.6))

313

32.505

240

100

13.55

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

185

13.2xt

13.2*.2

31.3

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected
Conveyor 5
1.00 INPUT DATA
1.01 Feeder Load

30

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

480

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

55

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

30 / 0.8

3 x V

0.95x3 x 0.415

Size of 185 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 337x1x0.65

2.03 Current carrying capacity of 185 sq.mm1 Run Cable

=
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos

0.8 (Assumed)
97 of 284

219 A

HZL-BTN-ELE-DS-SY-037
sin

0.6

55
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

480

1
Vdrop

%Vdrop

5.573

5.573

240

100

2.33

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

330

( 6 Times the full load current)

Drop at the time of Starting

330
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

480

1
Vdrop

%Vdrop

33.435

33.435

240

100

13.94

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

13.2xt

185

13.2*.2

31.3

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected
STOCKPILE AREA DSP SYSTEM PUMP
1.00 INPUT DATA
1.01 Feeder Load

30

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

560

1.04 AC resistance of the cable at 90C

0.161

/ km

1.05 Reactance of the cable at 50Hz

0.071

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

55

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

30 / 0.8
=

=
3 x V

0.95x3 x 0.415

Size of 240 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

240

1.0

399 A

(Ref : Power Engineers Handbook 25.66, Table 57)

98 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 399x1x0.65

2.03 Current carrying capacity of 240 sq.mm1 Run Cable

259 A

=
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

55
Vdrop

((0.000161 x 0.8) + (0.000071 x 0.6))

560

1
Vdrop

%Vdrop

5.279

5.279

240

100

2.2

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

330

( 6 Times the full load current)

Drop at the time of Starting

330
Vdrop

((0.000161 x 0.8) + (0.000071 x 0.6))

560

1
Vdrop

%Vdrop

31.675

31.675

240

100

13.2

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

240
13.2*.2

40.7

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x240sq.mm, Al conductor, Armoured, XLPE cable is selected

Conveyor 07 - Sag mill feed conveyor

1.00 INPUT DATA
1.01 Feeder Load

22

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

288

1.04 AC resistance of the cable at 90C

0.565

99 of 284

/ km

HZL-BTN-ELE-DS-SY-037
1.05 Reactance of the cable at 50Hz

0.074

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

40

/ km

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

22 / 0.8

=
3 x V x

0.95x3 x 0.415

Size of 70 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 179x1x0.65

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

116 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

40

1
5.719
5.719
240

((0.000565 x 0.8) + (0.000074 x 0.6))

288

V
x

100

2.39

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

240

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

240

1
34.311
34.311
240

((0.000565 x 0.8) + (0.000074 x 0.6))

288

V
x

100

14.3

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
100 of 284

HZL-BTN-ELE-DS-SY-037
Iw

70

13.2xt

13.2*.2

11.9

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
Sag mill discharge classification screen
1.00 INPUT DATA
1.01 Feeder Load

22

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

255

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

40

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

22 / 0.8

3 x V x

0.95x3 x 0.415

Size of 70 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 179x1x0.65

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

116 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

40

1
5.063
5.063
240

((0.000565 x 0.8) + (0.000074 x 0.6))

V
x

100

2.11

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

240

( 6 Times the full load current)

101 of 284

255

HZL-BTN-ELE-DS-SY-037
Drop at the time of Starting
Vdrop

Vdrop

%Vdrop

240

((0.000565 x 0.8) + (0.000074 x 0.6))

255

30.38
30.38

240

100

12.66

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
s
70
Iw
=
=
13.2*.2
13.2xt

11.9

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Scav. Froth & Pb cleaner I Tailing Pump 1(VFD)
1.00 INPUT DATA
1.01 Feeder Load

22

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

328

1.04 AC resistance of the cable at 90C

0.818

/ km

1.05 Reactance of the cable at 50Hz

0.075

/ km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

40

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

3 x V x

22 / 0.8

0.95x3 x 0.415

Size of 50 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

50

1.0

142 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 50 sq.mm1 Run Cable

142*1*0.65

=
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
=

(R cos + X sin)

Where,
102 of 284

92

HZL-BTN-ELE-DS-SY-037

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

40

1
9.176

((0.000818 x 0.8) + (0.000075 x 0.6))

328

9.176

240

100

3.83

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
For VFD

120

( 3 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

120

1
27.528

((0.000818 x 0.8) + (0.000075 x 0.6))

328

27.528

240

100

11.47

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

50

13.2xt

13.2*.2

8.47

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x50sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Rougher Spillage Pump 2
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

291

1.04 AC resistance of the cable at 90C

0.818

/ km

1.05 Reactance of the cable at 50Hz

0.075

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
15 / 0.8

P
IFL

=
3 x V x

=
0.95x3 x 0.415

Size of 50 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

50

1.0

142 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

103 of 284

HZL-BTN-ELE-DS-SY-037
Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 50 sq.mm1 Run Cable

142*1*0.65

92

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

27

1
5.495
5.495
240

((0.000818 x 0.8) + (0.000075 x 0.6))

291

V
x

100

2.29

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

162

1
32.971
32.971
240

((0.000818 x 0.8) + (0.000075 x 0.6))

291

V
x

100

13.74

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
50
s
Iw
=
=
13.2*.2
13.2xt

8.47

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x50sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Concentrate Filter feed Pumps No.20 (VFD)
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

290

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
104 of 284

HZL-BTN-ELE-DS-SY-037
IFL

15 / 0.8

3 x V x

3 x 0.415x 0.95

27

Size of 25 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 25 sq.mm1 Run Cable

96*1*0.65

=
=

62

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

27
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

290

1
Vdrop

%Vdrop

9.962

9.962

240

100

4.16

Permissible voltage drop is 5% on 240V basis hence ok

3.02 Check for Starting Current
For VFD

81

( 3 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

81

((0.00153 x 0.8) + (0.0000805 x 0.6))

290

29.886
29.886

240

100

12.46

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

25
13.2*.2

4.23

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected

105 of 284

HZL-BTN-ELE-DS-SY-037
Pb filter area spillage pump
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

365

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

15 / 0.8

3 x V x

3 x 0.415x 0.95

Size of 70 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

179*1*0.65

=
=

116 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

27

1
4.892
4.892
240

((0.000565 x 0.8) + (0.000074 x 0.6))

365

V
x

100

2.04

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

162
1

((0.000565 x 0.8) + (0.000074 x 0.6))

106 of 284

365

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

29.352

29.352

240

100

12.23

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
s
70
Iw
=
=
13.2xt
13.2*.2

KA/0.2Sec

11.9

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner III Concentrate Froth pump
1.00 INPUT DATA
1.01 Feeder Load

55

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

260

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
55 / 0.8

P
IFL

3 x V
2.02

101

0.95*3 x 0.415

Size of 185 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 185 sq.mm1 Run Cable

337*1*0.65

=
=

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop
=
x
n

(R cos + X sin)

219 A

Where,
cos

0.8 (Assumed)

sin

0.6

101
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

1
107 of 284

260

HZL-BTN-ELE-DS-SY-037

Vdrop

%Vdrop

5.543

5.543

240

100

2.31

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

606

( 6 Times the full load current)

Drop at the time of Starting

606
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

260

1
Vdrop

%Vdrop

33.258

33.258

240

100

13.86

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

185
13.2*.2

31.3

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected

108 of 284

HZL-BTN-ELE-DS-SY-037

LT CABLE SIZING CALCULATION

Zn scavenger cell 5
1.00 INPUT DATA
1.01 Feeder Load

90

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

305

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

90 / 0.8

3 x V x
2.02

165

0.95x3 x 0.415

Size of 185 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 185 sq.mm2 Run Cable

337*2*0.65

=
=

438 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
=

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

165

Vdrop

Vdrop

%Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

2
5.311
5.311
240

V
x

100

2.22

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

990

( 6 Times the full load current)

109 of 284

305

HZL-BTN-ELE-DS-SY-037
Drop at the time of Starting
990
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

305

2
Vdrop

%Vdrop

31.868

31.868

240

100

13.28

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

185

13.2xt

= 31.3

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 2 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Scavenger cell 6
1.00 INPUT DATA
1.01 Feeder Load

90

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

310

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

90 / 0.8

=
3 x V x

165

0.95x3 x 0.415

Size of 185 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 185 sq.mm2 Run Cable

337 x 2 x 0.65

=
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
=

x (R cos + X sin) x
n
110 of 284

438 A

HZL-BTN-ELE-DS-SY-037
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

165

2
5.398

((0.00021 x 0.8) + (0.0000718 x 0.6))

310

5.398

240

100

2.25

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

990

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

990

((0.00021 x 0.8) + (0.0000718 x 0.6))

310

32.39
32.39

100

240

13.5

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

185

13.2xt

13.2*.2

= 31.3

KA/0.2Sec

(Fuse Operated)

3.04 2 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Scavenger cell 7
1.00 INPUT DATA
1.01 Feeder Load

90

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

315

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

P
3 x V x

90 / 0.8
0.95x3 x 0.415

165

Size of 185 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

111 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 185 sq.mm2 Run Cable

337*2*0.65

438 A

=
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

165
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

315

2
Vdrop

%Vdrop

5.485

5.485

100

240

2.29

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

990

( 6 Times the full load current)

Drop at the time of Starting

990
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

315

2
Vdrop

%Vdrop

32.913

32.913

240

100

13.72

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

185
13.2*.2

= 31.3

(Fuse Operated)

KA/0.2Sec

3.04 2 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Scavenger cell 8
1.00 INPUT DATA
1.01 Feeder Load

90

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

320

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

112 of 284

HZL-BTN-ELE-DS-SY-037
1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

90 / 0.8

3 x V x

165

0.95x3 x 0.415

Size of 185 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 185 sq.mm2 Run Cable

337 x 2 x 0.65
=

438 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

165
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

320

2
Vdrop

%Vdrop

5.573
0
240

100

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

990

( 6 Times the full load current)

Drop at the time of Starting

990
Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

320

2
Vdrop

%Vdrop

33.435
33.435
240

V
x

100

13.94

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

113 of 284

HZL-BTN-ELE-DS-SY-037
3.03 Short Time rating of the Cable
Iw

185

13.2xt

= 31.3

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 2 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Rougher Concentrate Forth Pump
1.00 INPUT DATA
1.01 Feeder Load

75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

320

1.04 AC resistance of the cable at 90C

0.264

1.05 Reactance of the cable at 50Hz

0.0716 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

75 / 0.8

3 x V x
2.02

137

0.95x3 x 0.415

Size of 150 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
150

1.0

292 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 150 sq.mm2 Run Cable

292*2*0.65

=
=

380 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

137
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

2
Vdrop

%Vdrop

5.571
5.571
240

V
x

100

2.33

With in the Permissible limit of 2.5% voltage drop hence ok

114 of 284

320

HZL-BTN-ELE-DS-SY-037

3.02 Check for Starting Current

DOL or Squirrelcage Motor

822

( 6 Times the full load current)

Drop at the time of Starting

822
Vdrop

((0.000264 x 0.8) + (0.0000716 x 0.6))

75

2
Vdrop

%Vdrop

33.427
33.427

240

100

13.93

It is to be noted that motor has been selected to start upto 80% of rated voltage

3.03 With in the Permissible limit of 15% voltage drop hence ok

Short Time rating of the Cable
Iw

150

13.2xt

= 25.4

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 2 run of 1.1kV grade, 3.5C x150sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner I Cell 9
1.00 INPUT DATA
1.01 Feeder Load

75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

285

1.04 AC resistance of the cable at 90C

0.129

1.05 Reactance of the cable at 50Hz

0.0705 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
75 / 0.8

P
IFL

=
3 x V x

137

0.95*3 x 0.415

Size of 300 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

300

1.0

455 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 300 sq.mm1 Run Cable

= 0.65
455*1*0.65

=
=

115 of 284

296 A

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

137

1
5.681

((0.000129 x 0.8) + (0.0000705 x 0.6))

285

5.681

100

240

2.37

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

822

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

822

((0.000129 x 0.8) + (0.0000705 x 0.6))

285

34.086
34.086

240

100

14.21

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

300

13.2xt

13.2*.2

(Fuse Operated)

KA/0.2Sec

= 50.8

3.04 1 run of 1.1kV grade, 3.5C x300sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner I Cell 10
1.00 INPUT DATA
1.01 Feeder Load

75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

290

1.04 AC resistance of the cable at 90C

0.129

1.05 Reactance of the cable at 50Hz

0.0705 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

75 / 0.8
=

3 x V x

=
0.95*3 x 0.415
116 of 284

137

HZL-BTN-ELE-DS-SY-037
Size of 300 Sq.mm 3.5core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

300

1.0

455 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 300 sq.mm1 Run Cable

455*1*0.65

=
=

296 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

137
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

290

1
Vdrop

%Vdrop

5.781

5.781

240

100

2.41

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

822

( 6 Times the full load current)

Drop at the time of Starting

822
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

290

1
Vdrop

%Vdrop

34.684
34.684

240

100

14.46

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

300
13.2*.2

= 50.8

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x300sq.mm, Al conductor, Armoured, XLPE cable is selected

117 of 284

HZL-BTN-ELE-DS-SY-037
Zn Cleaner I Cell 11
1.00 INPUT DATA
1.01 Feeder Load

75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

295

1.04 AC resistance of the cable at 90C

0.129

1.05 Reactance of the cable at 50Hz

0.0705 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

75 / 0.8

3 x V x

0.95*3 x 0.415

137

Size of 300 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
1.0

300

455 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.04 Current carrying capacity of 300 sq.mm1 Run Cable

455*1*0.65

=
=

296 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

137
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

295

1
Vdrop

%Vdrop

5.88
5.88
240

V
x

100

2.45

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

822

( 6 Times the full load current)

Drop at the time of Starting

822
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

1
118 of 284

295

HZL-BTN-ELE-DS-SY-037

Vdrop

%Vdrop

35.282

35.282

240

100

14.71

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

300

13.2xt

= 50.8

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x300sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Concentrate Thickener underflow pumps - VFD
1.00 INPUT DATA
1.01 Feeder Load

22

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

328

1.04 AC resistance of the cable at 90C

0.818

/ km

1.05 Reactance of the cable at 50Hz

0.075

/ km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

40

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

22 / 0.8

=
3 x V

=
3 x 0.415x 0.95

Size of 50 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

50

1.0

142 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 50 sq.mm1 Run Cable

142*1*0.65

=
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

119 of 284

92

HZL-BTN-ELE-DS-SY-037

40
Vdrop

((0.000818 x 0.8) + (0.000075 x 0.6))

328

1
Vdrop

%Vdrop

9.176

9.176

240

100

3.83

3.02 With in the Permissible limit of 5% voltage drop hence ok

Check for Starting Current
For VFD

120

( 3 Times the full load current)

Drop at the time of Starting

120
Vdrop

((0.000818 x 0.8) + (0.000075 x 0.6))

328

1
Vdrop

%Vdrop

27.528

27.528

240

100

11.47

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

50

13.2xt

13.2*.2

= 8.47

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x50sq.mm, Al conductor, Armoured, XLPE cable is selected
Lime circuit cyclone feed pumps
1.00 INPUT DATA
1.01 Feeder Load

22

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

320

1.04 AC resistance of the cable at 90C

0.409

1.05 Reactance of the cable at 50Hz

0.0724 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

40

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

22 / 0.8
=

=
3 x V x

3 x 0.415x 0.95

Size of 95 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

95

1.0

221 A

(Ref : Power Engineers Handbook 25.66, Table 57)

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HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 95 sq.mm,1 Run Cable

221*1*0.65

144 A

=
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

40
Vdrop

((0.000409 x 0.8) + (0.0000724 x 0.6))

320

1
Vdrop

%Vdrop

4.744

4.744

240

100

1.98

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

240

( 6 Times the full load current)

Drop at the time of Starting

240
Vdrop

((0.000409 x 0.8) + (0.0000724 x 0.6))

320

2
Vdrop

%Vdrop

12.761

12.761

240

100

5.32

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

95
13.2*.2

= 16.1

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x95sq.mm, Al conductor, Armoured, XLPE cable is selected
Wet Type Fan in Main MCC
1.00 INPUT DATA
1.01 Feeder Load

20

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

20

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

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HZL-BTN-ELE-DS-SY-037
=

0.65

37

1.08 Current derating factors

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

20 / 0.8

3 x V x

0.95x3 x 0.415

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

37
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

20

1
Vdrop

%Vdrop

1.48
1.48
240

V
x

100

0.62

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

222

( 6 Times the full load current)

Drop at the time of Starting

222
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

20

2
Vdrop

%Vdrop

4.441
4.441
240

V
x

100

1.86

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

122 of 284

HZL-BTN-ELE-DS-SY-037
3.03 Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Total Power for +AL2 Cabinet
1.00 INPUT DATA
1.01 Feeder Load

20

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

260

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

1.06 Allowable Voltage Drop

0.0805 / km

2.00 Calculation
2.01 Full load current rating of the Feeder
20 / 0.8

P
IFL

=
3 x V

2.02

35

3 x 0.415

Size of 25 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 96x1x0.65

2.03 Current carrying capacity of 25 sq.mm1 Run Cable

62

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
=

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

35

Vdrop

Vdrop

%Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

1
11.578
11.578
240

V
x

100

4.83

3.02 With in the Permissible limit of 5% voltage drop hence ok

123 of 284

260

HZL-BTN-ELE-DS-SY-037
Short Time rating of the Cable
Iw

25

13.2xt

= 4.23

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.03 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Rougher Spillage Pump 1
1.00 INPUT DATA
1.01 Feeder Load

18.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

286

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

34

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

18.5 / 0.8

=
3 x V

0.95x3 x 0.415

Size of 70 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

179 x 1 x 0.65

=
=

116 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

34
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

1
Vdrop

%Vdrop

4.827
4.827
240

V
x

100

2.02

With in the Permissible limit of 2.5% voltage drop hence ok

124 of 284

286

HZL-BTN-ELE-DS-SY-037

3.02 Check for Starting Current

DOL or Squirrelcage Motor

204

( 6 Times the full load current)

Drop at the time of Starting

204
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

286

1
Vdrop

%Vdrop

28.962

28.962

240

100

12.07

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

70

13.2xt

= 11.9

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner spillage Pump
1.00 INPUT DATA
1.01 Feeder Load

18.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

325

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

30

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

18.5 / 0.8

=
3 x V

0.95x3 x 0.415

Size of 70 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

= 0.65
179*1*0.65

=
=

125 of 284

116 A

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

30
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

325

1
Vdrop

%Vdrop

4.84

4.84

240

100

2.02

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

180

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

180

1
29.039

((0.000565 x 0.8) + (0.000074 x 0.6))

325

29.039

240

100

12.1

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

70

13.2xt

13.2*.2

= 11.9

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner area spillage pump
1.00 INPUT DATA
1.01 Feeder Load

18.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

265

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

34

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

18.5 / 0.8
=

3 x V x

=
0.95x3 x 0.415
126 of 284

HZL-BTN-ELE-DS-SY-037

Size of 70 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

179*1*0.65

=
=

116 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL

Vdrop

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

34
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

265

1
Vdrop

%Vdrop

4.473
4.473

240

100

1.87

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

204

( 6 Times the full load current)

Drop at the time of Starting

204
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

265

1
Vdrop

%Vdrop

26.835

26.835

240

100

11.19

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

70
13.2*.2

= 11.9

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected

127 of 284

HZL-BTN-ELE-DS-SY-037
Pb Concentrate Storage tank agitator
1.00 INPUT DATA
1.01 Feeder Load

18.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

325

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

34

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

18.5 / 0.8

3 x V x

3 x 0.415x 0.95

Size of 70 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

179*1*0.65

=
=

116 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

34

1
5.485
5.485
240

((0.000565 x 0.8) + (0.000074 x 0.6))

325

V
x

100

2.29

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

204

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

204
=

((0.000565 x 0.8) + (0.000074 x 0.6))

1
128 of 284

325

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

32.911
32.911

240

100

13.72

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

70

13.2xt

= 11.9

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
PB CONCENTRATE FILTER HYDRALIC UNIT
1.00 INPUT DATA
1.01 Feeder Load

18.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

292

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

32

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

18.5 / 0.8

=
3 x 0.415

3 x V

Size of 70 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

179*1*0.65

=
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

129 of 284

116 A

HZL-BTN-ELE-DS-SY-037
32
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

292

1
Vdrop

%Vdrop

4.638

4.638

240

100

1.94

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

192

( 6 Times the full load current)

Drop at the time of Starting

192
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

292

1
Vdrop

%Vdrop

27.83
27.83

240

100

11.6

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

70

13.2xt

13.2*.2

= 11.9

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
PB FILTER MANIFOLD WASH WATER PUMPS
1.00 INPUT DATA
1.01 Feeder Load

18.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

368

1.04 AC resistance of the cable at 90C

0.409

1.05 Reactance of the cable at 50Hz

0.0724 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

34

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

18.5 / 0.8

=
3 x V

3 x 0.415x 0.95

Size of 95 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

95

1.0

221 A

(Ref : Power Engineers Handbook 25.66, Table 57)

130 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 95 sq.mm1 Run Cable

221*1*0.65

144 A

=
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

34

240

368

4.637
4.637

((0.000409 x 0.8) + (0.0000724 x 0.6))

100

1.94

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor
=
Drop at the time of Starting

204

( 6 Times the full load current)

204
Vdrop

((0.000409 x 0.8) + (0.0000724 x 0.6))

368

1
Vdrop

%Vdrop

27.825
27.825
240

V
x

100

11.6

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
s
95
Iw
=
=
13.2xt
13.2*.2

= 16.1

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x95sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Concentrate stockpile area spillage pump
1.00 INPUT DATA
1.01 Feeder Load

18.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

295

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

131 of 284

HZL-BTN-ELE-DS-SY-037
2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

18.5 / 0.8

34

3 x V

3 x 0.415x 0.95

Size of 70sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

179*1*0.65

=
=

116 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

34

1
4.979

((0.000565 x 0.8) + (0.000074 x 0.6))

295

4.979

100

240

2.08

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

204

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

204

((0.000565 x 0.8) + (0.000074 x 0.6))

1
29.873

295

29.873

240

100

12.45

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

70
13.2*.2

= 11.9

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
132 of 284

HZL-BTN-ELE-DS-SY-037
Tailings thickener underflow pumps -VFD
1.00 INPUT DATA
1.01 Feeder Load

18.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

349

1.04 AC resistance of the cable at 90C

1.11

/ km

1.05 Reactance of the cable at 50Hz

0.0783 / km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

34

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

18.5 / 0.8
=

=
3 x 0.415x 0.95

3 x V x

Size of 35 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70sq.mm,1 Run Cable

117*1*0.65

=
=

76

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

34

Vdrop

Vdrop

%Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

349

1
11.094
11.094
240

V
x

100

4.63

With in the Permissible limit of 5% voltage drop hence ok

3.02 Check for Starting Current
For VFD

102

( 3 Times the full load current)

Drop at the time of Starting

Vdrop

102
1

((0.00111 x 0.8) + (0.0000783 x 0.6))

133 of 284

349

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

33.283
33.283

240

100

13.87

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

35

13.2xt

KA/0.2Sec

= 5.93

13.2*.2

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
Conveyor 6
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

332

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

15 / 0.8

=
3 x V

0.95x3 x 0.415

Size of 70 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 179x1x0.65

2.03 Current carrying capacity of sq.mm1 Run Cable

=
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

=
n

Where,
cos

0.8 (Assumed)

sin

0.6
134 of 284

116 A

HZL-BTN-ELE-DS-SY-037
27
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

332

1
Vdrop

%Vdrop

4.45
4.45

100

240

1.86

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

162
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

332

1
Vdrop

%Vdrop

26.698

26.698

240

100

11.13

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

70

13.2xt

13.2*.2

= 11.9

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Rougher concentrate froth pump
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

295

1.04 AC resistance of the cable at 90C

0.818

/ km

1.05 Reactance of the cable at 50Hz

0.075

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

15 / 0.8

=
3 x V

=
0.95*3 x 0.415

Size of 50 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

50

1.0

142 A

(Ref : Power Engineers Handbook 25.66, Table 57)

135 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 142x1x0.65

2.03 Current carrying capacity of sq.mm1 Run Cable

92

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

27
Vdrop

((0.000818 x 0.8) + (0.000075 x 0.6))

295

1
Vdrop

%Vdrop

5.571

5.571

240

100

2.33

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

162
Vdrop

((0.000818 x 0.8) + (0.000075 x 0.6))

295

1
Vdrop

%Vdrop

33.424

33.424

240

100

13.93

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

50
13.2*.2

= 8.47

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x50sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Float area spillage pumps
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

334

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

136 of 284

HZL-BTN-ELE-DS-SY-037

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

15 / 0.8

=
3 x V

0.95*3 x 0.415

Size of 70 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 179x1x0.65

2.03 Current carrying capacity of sq.mm Run Cable

116 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

27
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

334

1
Vdrop

%Vdrop

4.477
4.477
240

V
x

100

1.87

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

162
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

334

1
Vdrop

%Vdrop

26.859
26.859
240

V
x

100

11.2

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

137 of 284

HZL-BTN-ELE-DS-SY-037
3.03 Short Time rating of the Cable
Iw

70

13.2xt

= 11.9

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Cleaner III cell 1
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

307

1.04 AC resistance of the cable at 90C

0.818

/ km

1.05 Reactance of the cable at 50Hz

0.075

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

15 / 0.8

=
3 x V

0.95x3 x 0.415

Size of 50 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

50

1.0

142 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 50 sq.mm1 Run Cable

142*1*0.65

=
=

92

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

27

1
5.797
5.797
240

((0.000818 x 0.8) + (0.000075 x 0.6))

V
x

100

2.42

With in the Permissible limit of 2.5% voltage drop hence ok

138 of 284

307

HZL-BTN-ELE-DS-SY-037

3.02 Check for Starting Current

DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

162
Vdrop

((0.000818 x 0.8) + (0.000075 x 0.6))

307

1
Vdrop

%Vdrop

34.784

34.784

240

100

14.5

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

50

13.2xt

= 8.47

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x50sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Cleaner II Cell 2
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

315

1.04 AC resistance of the cable at 90C

0.818

/ km

1.05 Reactance of the cable at 50Hz

0.075

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

15 / 0.8

=
3 x V

0.95x3 x 0.415

Size of 50 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

50

1.0

142 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 50 sq.mm1 Run Cable

= 0.65
142*1*0.65

=
=

139 of 284

92

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

27
Vdrop

((0.000818 x 0.8) + (0.000075 x 0.6))

315

1
Vdrop

%Vdrop

5.948

5.948

240

100

2.48

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

162
Vdrop

((0.315 x 0.8) + (0.000818 x 0.6))

315

1
Vdrop

%Vdrop

35.69

35.69

240

100

14.88

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

13.2xt

50

13.2*.2

KA/0.2Sec

= 8.47

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x50sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Cleaner II Cell 3
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

317

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

15 / 0.8
=

=
3 x V

0.95x3 x 0.415
140 of 284

HZL-BTN-ELE-DS-SY-037
Size of 70 Sq.mm 3.5core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

142 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

142*1*0.65

=
=

92

3.00 Check for voltage drop

3.01 Voltage drop
IFL

Vdrop

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

27
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

317

1
Vdrop

%Vdrop

4.249

4.249

240

100

1.78

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

162
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

317

1
Vdrop

%Vdrop

25.492

25.492

240

100

10.63

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

70
13.2*.2

= 11.9

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected

141 of 284

HZL-BTN-ELE-DS-SY-037
Pb Cleaner I cell 4
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

325

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

15 / 0.8

=
3 x V

0.95x3 x 0.415

Size of 70 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

179*1*0.65

=
=

116 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

27

Vdrop

Vdrop

%Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

325

1
4.356
4.356
240

V
x

100

1.82

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

162
1

((0.000565 x 0.8) + (0.000074 x 0.6))

142 of 284

325

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

26.135

26.135

240

100

10.89

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

70

13.2xt

KA/0.2Sec

= 11.9

13.2*.2

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Cleaner I cell 5
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

305

1.04 AC resistance of the cable at 90C

0.818

/ km

1.05 Reactance of the cable at 50Hz

0.075

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

3 x V

15 / 0.8
0.95x3 x 0.415

Size of 50 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
2.02
Cable size
Current Rating at 35C
Temperature 35C
50

1.0

142 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 50 sq.mm1 Run Cable

= 142*1*0.65
=

92

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

27
Vdrop

((0.000818 x 0.8) + (0.000075 x 0.6))

1
143 of 284

305

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

5.76

5.76

240

100

2.4

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

162
Vdrop

((0.000818 x 0.8) + (0.000075 x 0.6))

305

1
Vdrop

%Vdrop

34.557

34.557

240

100

14.4

With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

50

13.2xt

= 8.47

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x50sq.mm, Al conductor, Armoured, XLPE cable is selected
Reagent EOT
1.00 INPUT DATA
1.01 Feeder Load

5.05

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

240

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

=
3 x V

2.02

5.05 / 0.8
=

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

70 A

1.0

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8

Total factor to be applied for arriving the capacity

144 of 284

= 0.65

HZL-BTN-ELE-DS-SY-037
= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
9

Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

240

1
Vdrop

%Vdrop

4.321

4.321

240

100

1.81

With in the Permissible limit of 2.5% voltage drop hence ok

3.02 Check for Starting Current
DOL or Squirrelcage Motor

54

( 6 Times the full load current)

Drop at the time of Starting

54
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

240

1
Vdrop

%Vdrop

25.926
25.926
240

V
x

100

10.81

3.03 With in the Permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

s
13.2xt

16
13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected

145 of 284

HZL-BTN-ELE-DS-SY-037

LT CABLE SIZING CALCULATION

TOTAL POWER FOR +AL2 CABINET (STANDBY BALL MILL)
1.00 INPUT DATA
1.01 Feeder Load

65

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

260

1.04 AC resistance of the cable at 90C

0.409

1.05 Reactance of the cable at 50Hz

0.0724 / km

1.06 Allowable Voltage Drop

1.07 Current derating factor

0.65

/ km
%

2.00 Calculation
2.01 Full load current rating of the Feeder

2.02

IFL

65 / 0.8

3 x V

3 x 0.415

113

Size of 95 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
95

1.0

221 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 221x1x0.65

2.03 Current carrying capacity of 95 sq.mm1 Run Cable

144 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

113

1
10.889

((0.000409 x 0.8) + (0.0000724 x 0.6))

260

10.889

240

100

4.54

3.02 With in the Permissible limit of 5% voltage drop hence ok

Short Time rating of the Cable
Iw

s
13.2xt

95
13.2*.2

16.1

KA/0.2Sec

(Fuse Operated)

3.03 1 run of 1.1kV grade, 3.5C x95sq.mm, Al conductor, Armoured, XLPE cable is selected
146 of 284

HZL-BTN-ELE-DS-SY-037
TOTAL POWER FOR +AL1 CABINET (STANDBY BALL MILL)
1.00 INPUT DATA
1.01 Feeder Load

80

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

260

1.04 AC resistance of the cable at 90C

0.323

1.05 Reactance of the cable at 50Hz

0.0712 / km

1.06 Allowable Voltage Drop

1.07 Current derating factor

0.65

/ km
%

2.00 Calculation
2.01 Full load current rating of the Feeder
P

80 / 0.8

IFL

3 x V

139

3 x 0.415

Size of 120 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

120

1.0

257 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 257x1x0.65

2.03 Current carrying capacity of 120 sq.mm1 Run Cable

167 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

139
Vdrop

((0.000323 x 0.8) + (0.0000712 x 0.6))

260

1
Vdrop

%Vdrop

10.882
10.882

240

100

4.54

3.02 With in the Permissible limit of 5% voltage drop hence ok

Short Time rating of the Cable
Iw

s
13.2xt

120
13.2*.2

20.3

KA/0.2Sec

(Fuse Operated)

3.03 1 run of 1.1kV grade, 3.5C x120sq.mm, Al conductor, Armoured, XLPE cable is selected
147 of 284

HZL-BTN-ELE-DS-SY-037
TOTAL POWER FOR +AL2 CABINET (STANDBY SAG MILL)
1.00 INPUT DATA
1.01 Feeder Load

60

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

245

1.04 AC resistance of the cable at 90C

0.409

1.05 Reactance of the cable at 50Hz

0.0724 / km

1.06 Allowable Voltage Drop

1.07 Current derating factor

0.65

/ km
%

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

60 / 0.8

3 x V

104

3 x 0.415

Size of 95 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

95

1.0

221 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 221x1x0.65

2.03 Current carrying capacity of 95 sq.mm1 Run Cable

144 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

104
Vdrop

((0.000409 x 0.8) + (0.0000724 x 0.6))

245

1
Vdrop

%Vdrop

9.444
9.444

240

100

3.94

3.02 With in the Permissible limit of 5% voltage drop hence ok

Short Time rating of the Cable
Iw

s
13.2xt

95
13.2*.2

16.1

KA/0.2Sec

(Fuse Operated)

3.03 1 run of 1.1kV grade, 3.5C x95sq.mm, Al conductor, Armoured, XLPE cable is selected
148 of 284

HZL-BTN-ELE-DS-SY-037
TOTAL POWER FOR +AL1 CABINET (STANDBY SAG MILL)
1.00 INPUT DATA
1.01 Feeder Load

80

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

245

1.04 AC resistance of the cable at 90C

0.323

1.05 Reactance of the cable at 50Hz

0.0712 / km

1.06 Allowable Voltage Drop

1.07 Current derating factor

0.65

/ km
%

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

80 / 0.8

3 x V
2.02

139

3 x 0.415

Size of 120 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
120

1.0

257 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 257x1x0.65

2.03 Current carrying capacity of 120 sq.mm1 Run Cable

167 A

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

139
Vdrop

((0.000323 x 0.8) + (0.0000712 x 0.6))

245

1
Vdrop

%Vdrop

10.255
10.255

240

100

4.28

3.02 With in the Permissible limit of 5% voltage drop hence ok

Short Time rating of the Cable
Iw

s
13.2xt

120
13.2*.2

20.3

KA/0.2Sec

(Fuse Operated)

3.03 1 run of 1.1kV grade, 3.5C x120sq.mm, Al conductor, Armoured, XLPE cable is selected
149 of 284

HZL-BTN-ELE-DS-SY-037
TAILING DISPOSAL PUMPS - TRAIN 1/TRAIN 2 VFD
1.00 INPUT DATA
1.01 Feeder Load

90

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

342

1.04 AC resistance of the cable at 90C

0.21

/ km

1.05 Reactance of the cable at 50Hz

0.0718 / km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factor

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

90 / 0.8

3 x V x

3 x 0.415x 0.95

165

Size of 185 Sq.mm 3.5 core Aluminium cable is selected for checking.
Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 185 sq.mm,1 Run Cable

337*1*0.65

=
=

219 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
x

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

165

Vdrop

Vdrop

((0.00021 x 0.8) + (0.0000718 x 0.6))

342

1
11.911

11.911
x 100
=
4.97
%
240
3.02 With in the Permissible limit of 5% voltage drop hence ok
Check for Starting Current
(3 Times the full load current)
For VFD
= 495 A
Drop at the time of Starting
%Vdrop

Vdrop

495
x

((0.00021 x 0.8) + (0.0000718 x 0.6))

1
Vdrop

35.734

V
150 of 284

342

HZL-BTN-ELE-DS-SY-037
%Vdrop

35.734

240

100

14.89

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

185

13.2xt

13.2*.2

31.3

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x185sq.mm, Al conductor, Armoured, XLPE cable is selected
PLANT AIR /FILTER AIR COMPRESSOR 1 /COMPRESSOR 2
1.00 INPUT DATA
1.01 Feeder Load

132

kW

1.04 Voltage rating

VT

0.415

kV

1.03 Length of the cable

327

1.04 AC resistance of the cable at 90C

0.129

1.05 Reactance of the cable at 50Hz

0.0705 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

132 / 0.8

=
3 x V x

242

3 x 0.415x 0.95

Size of 300 sq.mm 3.5 core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

300

1.0

455 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 455x2x0.65

2.03 current carrying capacity of 300 sq.mm 2 Run cable

592 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

242
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

2
151 of 284

327

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

5.757

5.757

240

100

2.4

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
= 1452 A

DOL or Squirrelcage Motor

( 6 Times the full load current)

Drop at the time of Starting

1452
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

327

2
Vdrop

%Vdrop

34.542

34.542

240

100

14.4

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

300

13.2xt

13.2*1

22.7

(ACB Operated)

KA/0.2Sec

2 runs of 1.1kV grade, 3.5C x300 sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Concentrate Storage tank agitator 1

1.00 INPUT DATA

1.01 Feeder Load

55

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

355

1.04 AC resistance of the cable at 90C

0.129

1.05 Reactance of the cable at 50Hz

0.0705 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

55 /0.8

=
3 x V x

101

3 x 0.415x 0.95

Size of 300 Sq.mm 3.5 core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

300

1.0

455 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

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HZL-BTN-ELE-DS-SY-037
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 300 sq.mm1 Run Cable

455*1*0.65

296 A

=
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

101
Vdrop

355

((0.000129 x 0.8) + (0.0000705 x 0.6))

1
Vdrop

%Vdrop

5.217

5.217

240

100

2.18

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

606

( 6 Times the full load current)

Drop at the time of Starting

606
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

355

1
%Vdrop

240

100

0.42

With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Permissible voltage drop is 15% on 240V basis hence voltage drop is ok
Short Time rating of the Cable
Iw

s
13.2xt

300
13.2*.2

50.8

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x300sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Filter 1 cloth wash water pumps
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

325

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
153 of 284

HZL-BTN-ELE-DS-SY-037
P
IFL

15 / 0.8

=
3 x V

2.02

27

3 x 0.415x 0.95

Size of 70 Sq.mm 3.5 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

179*1*0.65

=
=

116 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

27
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

325

1
Vdrop

%Vdrop

4.356

4.356

240

100

1.82

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

162
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

325

1
Vdrop

%Vdrop

26.135

26.135

240

100

10.89

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

70
13.2*.2

11.9

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected

154 of 284

HZL-BTN-ELE-DS-SY-037
Zn filter area spillage pump 1
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

335

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

15 / 0.8

=
3 x V

2.02

3 x 335x 0.95

Size of 70 Sq.mm 3.5 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

179*1*0.65

=
=

116 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos
sin

=
=

0.8 (Assumed)
0.6

27
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

335

1
Vdrop

%Vdrop

4.49
4.49
240

V
x

100

1.88

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

162
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

1
155 of 284

335

HZL-BTN-ELE-DS-SY-037

Vdrop

%Vdrop

26.94

26.94

240

100

11.23

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

70

13.2xt

13.2*.2

11.9

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn filter area spillage pump 2
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

338

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

15 / 0.8

3 x V

3 x 0.415x 0.95

Size of 70 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

179*1*0.65

=
=

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6
156 of 284

116 A

HZL-BTN-ELE-DS-SY-037
27
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

338

1
Vdrop

%Vdrop

4.53

4.53

240

100

1.89

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

162
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

338

1
Vdrop

%Vdrop

27.181

27.181

100

240

11.33

With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

70

13.2xt

13.2*.2

11.9

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected

Spillage Pump For Zinc Stockpile Area

1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

440

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

15 / 0.8
=

=
3 x V

3 x 0.415x 0.95

Size of 70 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

157 of 284

HZL-BTN-ELE-DS-SY-037
Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

179*1*0.65

116 A

=
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

27
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

440

1
Vdrop

%Vdrop

5.897

5.897

240

100

2.46

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

162
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

440

1
Vdrop

%Vdrop

35.383

35.383

100

240

14.75

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

70
13.2*.2

11.9

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
Tailings Area Spillage Pump
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

315

1.04 AC resistance of the cable at 90C

0.818

/ km

1.05 Reactance of the cable at 50Hz

0.075

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

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HZL-BTN-ELE-DS-SY-037
2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

15 / 0.8

3 x V

3 x 0.415x 0.95

27

Size of 50 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

50

1.0

142 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 50 sq.mm,1 Run Cable

142*1*0.65

=
=

92

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

27
Vdrop

((0.000818 x 0.8) + (0.000075 x 0.6))

315

1
Vdrop

%Vdrop

5.948
5.948

240

100

2.48

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

162

1
35.69

((0.000818 x 0.8) + (0.000075 x 0.6))

315

35.69

240

100

14.88

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

50
13.2*.2

8.47

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x50sq.mm, Al conductor, Armoured, XLPE cable is selected
159 of 284

HZL-BTN-ELE-DS-SY-037
Spillage pump in lime area
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

360

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
15 / 0.8

P
IFL

=
3 x 0.415x 0.95

3 x V x

Size of 70 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

179*1*0.65

=
=

116 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

27

1
4.825
4.825
240

((0.000565 x 0.8) + (0.000074 x 0.6))

360

V
x

100

2.02

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

162
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

1
160 of 284

360

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

28.95

28.95

240

100

12.07

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

70

13.2xt

13.2*.2

KA/0.2Sec

11.9

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
HOT WATER PUMP
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

360

1.04 AC resistance of the cable at 90C

0.565

/ km

1.05 Reactance of the cable at 50Hz

0.074

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

15 / 0.8

=
3 x V x

=
3 x 0.415x 0.95

Size of 70 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

70

1.0

179 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 70 sq.mm1 Run Cable

179*1*0.65

=
=

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6
161 of 284

116 A

HZL-BTN-ELE-DS-SY-037
27
Vdrop

((0.000565 x 0.8) + (0.000074 x 0.6))

360

1
Vdrop

%Vdrop

4.825

4.825

240

100

2.02

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

162

((0.000565 x 0.8) + (0.000074 x 0.6))

360

28.95
28.95

240

100

12.07

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

70

13.2xt

13.2*.2

11.9

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x70sq.mm, Al conductor, Armoured, XLPE cable is selected
Nigrosine Spillage Pump
1.00 INPUT DATA
1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

195

1.04 AC resistance of the cable at 90C

1.11

/ km

1.05 Reactance of the cable at 50Hz

0.0783 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

27

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

15 / 0.8
=

=
3 x V

3 x 0.415x 0.95

Size of 35 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

162 of 284

HZL-BTN-ELE-DS-SY-037
Factor for Non leaner loads

0.8

= 0.65

Total factor to be applied for arriving the capacity

= 117x1x0.65

2.03 current carrying capacity of 35sq.mm,1Run cable

76

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

27
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

195

1
Vdrop

%Vdrop

4.923

4.923

240

100

2.06

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

162
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

195

3.03

Vdrop

%Vdrop

29.536
29.536
240

100

12.31

With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

3.04

s
13.2xt

35

= 5.929

13.2*.2

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 3.5C x35 sq.mm, Al conductor, Armoured, XLPE cable is selected
MIBC Spillage pump

1.00 INPUT DATA

1.01 Feeder Load

15

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

202

1.04 AC resistance of the cable at 90C

1.11

/ km

1.05 Reactance of the cable at 50Hz

0.0783 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
163 of 284

HZL-BTN-ELE-DS-SY-037
P
IFL

15 / 0.8

=
3 x V

27

3 x 0.415x 0.95

Size of 35 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 117x1x0.65

2.03 current carrying capacity of 35sq.mm,1Run cable

76

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

27
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

202

1
Vdrop

%Vdrop

5.099

5.099

240

100

2.13

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

162

( 6 Times the full load current)

Drop at the time of Starting

162
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

202

3.03

Vdrop

%Vdrop

30.596
30.596
240

100

12.75

With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

3.04

s
13.2xt

35
13.2*.2

= 5.929

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 3.5C x35 sq.mm, Al conductor, Armoured, XLPE cable is selected

164 of 284

HZL-BTN-ELE-DS-SY-037
TOTAL POWER FOR AL2 CABINET CONTROL SOURCE (PERMANENT)
1.00 INPUT DATA
1.01 Feeder Load

10

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

260

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Current derating factors

0.65

17

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

10 / 0.8

=
3 x V

3 x 0.415

Size of 25 Sq.mm 4core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 96x1x0.65

2.03 Current carrying capacity of 25 sq.mm1 Run Cable

62

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

17

1
5.624

((0.00153 x 0.8) + (0.0000805 x 0.6))

260

5.624

240

100

2.35

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Short Time rating of the Cable
Iw

s
13.2xt

25
13.2*.2

4.23

KA/0.2Sec

(Fuse Operated)

303 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected
165 of 284

HZL-BTN-ELE-DS-SY-037
TOTAL POWER FOR AL2 CABINET CONTROL SOURCE (PERMANENT)
1.00 INPUT DATA
1.01 Feeder Load

10

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

260

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Current derating factors

0.65

17

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

10 / 0.8

=
3 x V

3 x 0.415

Size of 25 Sq.mm 4core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 96x1x0.65

2.03 Current carrying capacity of 25 sq.mm1 Run Cable

62

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

17

1
5.624

((0.00153 x 0.8) + (0.0000805 x 0.6))

260

5.624

240

100

2.35

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Short Time rating of the Cable
Iw

s
13.2xt

25
13.2*.2

4.23

KA/0.2Sec

(Fuse Operated)

3.03 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected
166 of 284

HZL-BTN-ELE-DS-SY-037
Total Power For AL2 Cabinet Control Source (Permanent)
1.00 INPUT DATA
1.01 Feeder Load

10

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

290

1.04 AC resistance of the cable at 90C

1.11

/ km

1.05 Reactance of the cable at 50Hz

0.0783 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Current derating factors

0.65

17

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

10 / 0.8

=
3 x V

3 x 0.415

Size of 35 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 117x1x0.65

2.03 Current carrying capacity of 35 sq.mm1 Run Cable

76

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

17

1
4.609

((0.00111 x 0.8) + (0.0000783 x 0.6))

290

4.609

240

100

1.93

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Short Time rating of the Cable
Iw

s
13.2xt

35
13.2*.2

5.93

KA/0.2Sec

(Fuse Operated)

3.03 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
167 of 284

HZL-BTN-ELE-DS-SY-037

Mill feed reciprocating feeders (VFD)

1.00 INPUT DATA
1.01 Feeder Load

7.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

270

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

14

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

7.5 / 0.8

3 x V

0.95x3 x 0.415

Size of 16 Sq.mm 4core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

14
Vdrop

Vdrop

%Vdrop

1
7.562
7.562
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

V
x

100

3.16

3.02 With in the Permissible limit of 5% voltage drop hence ok

Check for Starting Current
For VFD

42

( 3Times the full load current)

168 of 284

270

HZL-BTN-ELE-DS-SY-037
Drop at the time of Starting
42
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

270

1
Vdrop

%Vdrop

22.685
22.685

240

100

9.46

With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

16

13.2xt

13.2*.2

2.71

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb conditioner Agitator
1.00 INPUT DATA
1.01 Feeder Load

7.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

270

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

14

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

7.5 / 0.8

=
0.95x3 x 0.415

3 x V x

Size of 25 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 96x1x0.65

2.03 Current carrying capacity of sq.mm1 Run Cable

=
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
169 of 284

62

HZL-BTN-ELE-DS-SY-037
Where,
cos

0.8 (Assumed)

sin

0.6

14
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

1
Vdrop

%Vdrop

4.809

4.809

240

100

2.01

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

84

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

84

1
28.856

((0.00153 x 0.8) + (0.0000805 x 0.6))

270

28.856

240

100

12.03

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

25

13.2xt

13.2*.2

4.23

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Cleaner I Concentrate Froth Pump
1.00 INPUT DATA
1.01 Feeder Load

7.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

329

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

14

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

3 x V x

7.5 / 0.8
0.95x3 x 0.415

Size of 25 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
25

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

170 of 284

270

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 25 sq.mm1 Run Cable

70*1*0.65

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

14

Vdrop

Vdrop

%Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

329

1
5.86

5.86

240

100

2.45

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

84

( 6 Times the full load current)

Drop at the time of Starting

84
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

329

1
Vdrop

%Vdrop

35.161

35.161

240

100

14.66

With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
3.03 Short Time rating of the Cable
Iw

s
13.2xt

25
13.2*.2

4.23

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Scav Conc Peristatic House FeedPumps
1.00 INPUT DATA
1.01 Feeder Load

7.5

kW

1.04 Voltage rating

VT

0.415

kV

1.03 Length of the cable

285

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

1.06 Allowable Voltage Drop at normal running cond.

171 of 284

0.0805 / km
2.5

HZL-BTN-ELE-DS-SY-037
1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

14

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

7.5 / 0.8

=
3 x 0.415x 0.95

3 x V x

Size of 25 sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 25 sq.mm 1Run cable

96*1*0.65

=
=

62

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

14
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

285

1
Vdrop

%Vdrop

5.076
5.076
240

100

2.12

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

84

( 6 Times the full load current)

Drop at the time of Starting

84
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

285

1
Vdrop

%Vdrop

30.459
30.459
240

V
x

100

12.7

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
172 of 284

HZL-BTN-ELE-DS-SY-037
Short Time rating of the Cable
Iw
3.04

25

13.2xt

13.2*.2

4.23

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x25 sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Conditioner 1 Agitator

1.00 INPUT DATA

1.01 Feeder Load

7.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

250

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

14

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

7.5 / 0.8

3 x V x

0.95x3 x 0.415

Size of 25 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 25 sq.mm1 Run Cable

70*1*0.65

=
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

14
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

1
Vdrop

%Vdrop

4.453
4.453
240

V
x

100

1.86

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

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250

HZL-BTN-ELE-DS-SY-037
Check for Starting Current
DOL or Squirrelcage Motor

84

( 6 Times the full load current)

Drop at the time of Starting

84
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

250

1
Vdrop

%Vdrop

26.718

26.718

240

100

11.14

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

25

13.2xt

13.2*.2

4.23

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Conditioner 2 Agitator
1.00 INPUT DATA
1.01 Feeder Load

7.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

252

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

14

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

7.5 / 0.8

=
3 x V x

0.95x3 x 0.415

Size of 25 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 25 sq.mm1 Run Cable

= 0.65
96*1*0.65

=
=

3.00 Check for voltage drop

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62

HZL-BTN-ELE-DS-SY-037
3.01 Voltage drop
IFL

Vdrop

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

14
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

252

1
Vdrop

%Vdrop

4.489

4.489

240

100

1.88

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

84

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

84

1
26.932

((0.00153 x 0.8) + (0.0000805 x 0.6))

252

26.932

240

100

11.23

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

25

13.2*.2

4.23

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Cleaner 4 Sample Transfer Pumps
1.00 INPUT DATA
1.01 Feeder Load

7.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

285

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

14

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

7.5 / 0.8
=

=
3 x V x

=
3 x 0.415x 0.95

Size of 25 Sq.mm 4 core Aluminium cable is selected for checking.

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HZL-BTN-ELE-DS-SY-037
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 96x1x0.65

2.03 current carrying capacity of 25sq.mm,1Run cable

62

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin)

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

14

1
5.076

((0.00153 x 0.8) + (0.0000805 x 0.6))

285

5.076

100

240

2.12

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

84

( 6 Times the full load current)

Drop at the time of Starting

3.03

Vdrop

Vdrop

%Vdrop

84

1
30.459
30.459
240

((0.00153 x 0.8) + (0.0000805 x 0.6))

285

V
x

100

12.7

With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

3.04

s
13.2xt

25
13.2*.2

= 4.235

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 3.5C x25 sq.mm, Al conductor, Armoured, XLPE cable is selected
Conveyor 09 - Pb filter concentrate conveyor

1.00 INPUT DATA

1.01 Feeder Load

7.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

383

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HZL-BTN-ELE-DS-SY-037
1.04 AC resistance of the cable at 90C

1.05 Reactance of the cable at 50Hz

1.11

/ km

0.0783 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

14

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

7.5 / 0.8

=
3 x 0.415x 0.95

3 x V x

Size of 35 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 35 sq.mm1 Run Cable

117*1*0.65

=
=

76

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

14
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

383

1
Vdrop

%Vdrop

5.013
5.013
240

V
x

100

2.09

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
( 6 Times the full load current)
DOL or Squirrelcage Motor
= 84 A
Drop at the time of Starting
84
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

1
Vdrop

%Vdrop

30.08
30.08
240

V
x

100

12.54

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383

HZL-BTN-ELE-DS-SY-037
3.03 With in the permissible limit of 15% voltage drop hence ok
It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

35

13.2xt

13.2*.2

5.93

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
Conveyor 11
1.00 INPUT DATA
1.01 Feeder Load

7.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

425

1.04 AC resistance of the cable at 90C

1.11

/ km

1.05 Reactance of the cable at 50Hz

0.0783 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

14

2.00 Calculation
2.01 Full load current rating of the Feeder
7.5 / 0.8

P
IFL

=
3 x 0.415x 0.95

3 x V x

Size of 35 sq.mm 3.5C core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 35 sq.mm1 Run Cable

117*1*0.65

=
=

76

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

14
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

1
Vdrop

5.563

V
178 of 284

425

HZL-BTN-ELE-DS-SY-037
%Vdrop

5.563

240

100

2.32

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
( 6 Times the full load current)
DOL or Squirrelcage Motor
= 84 A
Drop at the time of Starting
84
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

425

1
Vdrop

%Vdrop

33.379

33.379

100

240

13.91

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

35

13.2xt

13.2*.2

KA/0.2Sec

5.93

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
Tailings disposal Tank Agitator
1.00 INPUT DATA
1.01 Feeder Load

7.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

312

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

14

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

7.5 / 0.8

=
3 x V x

3 x 0.415x 0.95

Size of 25 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 25 sq.mm,1 Run Cable

= 0.65
70*1*0.65

=
=

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46

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

14
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

312

1
Vdrop

%Vdrop

5.557

5.557

240

100

2.32

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

84

( 6 Times the full load current)

Drop at the time of Starting

84
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

312

1
Vdrop

%Vdrop

33.344

33.344

240

100

13.9

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

25

13.2xt

13.2*.2

4.23

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected
Tailings disposal gland seal pump 1
1.00 INPUT DATA
1.01 Feeder Load

7.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

342

1.04 AC resistance of the cable at 90C

1.11

/ km

1.05 Reactance of the cable at 50Hz

0.0783 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

14

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

P
3 x V x

7.5 / 0.8
3 x 0.415x 0.95

Size of 35 Sq.mm 3.5 core Aluminium cable is selected for checking.

180 of 284

HZL-BTN-ELE-DS-SY-037
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 240 sq.mm,3Run Cable

117*1*0.65

76

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

14
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

342

1
Vdrop

%Vdrop

4.477
4.477

240

100

1.87

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

84

( 6 Times the full load current)

Drop at the time of Starting

84
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

342

1
Vdrop

%Vdrop

26.86

26.86

240

100

11.2

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

35
13.2*1

2.65

KA/Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Cleaner III Concentrate Froth Pump
1.00 INPUT DATA
1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

181 of 284

HZL-BTN-ELE-DS-SY-037
1.03 Length of the cable

312

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 / 0.8

=
0.95x3 x 0.415

3 x V x

Size of 25 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 25 sq.mm1 Run Cable

96*1*0.65

=
=

62

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

10

1
3.97
3.97
240

((0.00153 x 0.8) + (0.0000805 x 0.6))

312

V
x

100

1.66

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

60

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

60

1
V

23.817
23.817
240

((0.00153 x 0.8) + (0.0000805 x 0.6))

100

9.93

3.03 With in the permissible limit of 15% voltage drop hence ok

182 of 284

312

HZL-BTN-ELE-DS-SY-037
It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

25

13.2xt

13.2*.2

(Fuse Operated)

KA/0.2Sec

4.23

3.04 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Cleaner II Concentrate Froth Pump
1.00 INPUT DATA
1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

324

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 / 0.8

3 x V x

0.95x3 x 0.415

Size of 25 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 25 sq.mm1 Run Cable

96*1*0.65

=
=

62

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

10

1
4.122
4.122
240

((0.00153 x 0.8) + (0.0000805 x 0.6))

V
x

100

1.72

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

183 of 284

324

HZL-BTN-ELE-DS-SY-037
Check for Starting Current
DOL or Squirrelcage Motor

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

324

1
Vdrop

%Vdrop

24.734

24.734

240

100

10.31

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

25

13.2xt

13.2*.2

4.23

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn SCAV.TAILS.SAMPLE PERISTATIC HOUSE PUMP(VFD)
1.00 INPUT DATA
1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

285

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

P
3 x V x

5.5 / 0.8

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 70x1x0.65
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
n

x (R cos + X sin)

184 of 284

46

HZL-BTN-ELE-DS-SY-037
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

10

1
5.701

((0.00244 x 0.8) + (0.0000808 x 0.6))

285

5.701

240

100

2.38

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
For VFD

30

( 3 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

30

1
17.104

((0.00244 x 0.8) + (0.0000808 x 0.6))

285

17.104

240

100

7.13

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 3.5C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn SCAV.CONC.SAMPLE PERISTATIC HOUSE PUMP(VFD)

1.00 INPUT DATA

1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

285

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 / 0.8
=

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

185 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

10
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

285

1
Vdrop

%Vdrop

5.701

5.701

240

100

2.38

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
For VFD

30

( 3 Times the full load current)

Drop at the time of Starting

30
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

285

1
Vdrop

%Vdrop

17.104
17.104
240

V
x

100

7.13

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

s
13.2xt

16
13.2*.2

2.71

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 3.5C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Duplex Particle Size Monitor For Sec. Cyclone & Reg. Cyclone O/f

1.00 INPUT DATA

1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

240

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

1.06 Allowable Voltage Drop at normal running cond.

186 of 284

0.0808 / km
2.5

HZL-BTN-ELE-DS-SY-037
1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 / 0.8

=
3 x V

3 x 0.415

Size of 16 Sq.mm 4core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

10
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

240

1
Vdrop

%Vdrop

4.801
4.801
240

V
x

100

2.01

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

240

1
Vdrop

%Vdrop

28.807
28.807
240

V
x

100

12.01

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

187 of 284

HZL-BTN-ELE-DS-SY-037
Short Time rating of the Cable
Iw

16

13.2xt

13.2*.2

2.71

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Particle Size Monitor For Pr. Class. Cyclone O/f Stream
1.00 INPUT DATA
1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

240

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 / 0.8

=
3 x V

3 x 0.415

Size of 16 Sq.mm 4core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

10
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

1
Vdrop

%Vdrop

4.801
4.801
240

V
x

100

2.01

188 of 284

240

HZL-BTN-ELE-DS-SY-037
3.02 With in the Permissible limit of 2.5% voltage drop hence ok
Check for Starting Current
DOL or Squirrelcage Motor

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

240

1
Vdrop

%Vdrop

28.807
28.807

240

100

12.01

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

16

13.2*.2

2.71

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Concentrate Thickener Overflow Pumps
1.00 INPUT DATA
1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

245

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 / 0.8
=

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 0.65
= 70x1x0.65
=

3.00 Check for voltage drop

3.01 Voltage drop
189 of 284

46

HZL-BTN-ELE-DS-SY-037
Vdrop

IFL

x (R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

10
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

245

1
Vdrop

%Vdrop

4.901
4.901

240

100

2.05

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

245

1
Vdrop

%Vdrop

29.407

29.407

240

100

12.26

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

13.2*.2

2.71

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 3.5C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Concentrate Thickener underflow pumps No.14 (VFD)

1.00 INPUT DATA

1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

286

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 / 0.8
=

3 x V

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

190 of 284

HZL-BTN-ELE-DS-SY-037
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

117*1*0.65

76

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

10
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

286

1
Vdrop

%Vdrop

5.721
5.721

240

100

2.39

3.02 With in the Permissible limit of 5% voltage drop hence ok

Check for Starting Current
For VFD

30

( 3 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

30

((0.00244 x 0.8) + (0.0000808 x 0.6))

1
17.164

286

17.164

240

100

7.16

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

16
13.2*.2

2.71

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Lime Storage Tank Agitator
1.00 INPUT DATA
1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

320

191 of 284

HZL-BTN-ELE-DS-SY-037
1.04 AC resistance of the cable at 90C

1.05 Reactance of the cable at 50Hz

1.53

/ km

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 / 0.8

=
3 x V

3 x 0.415x 0.95

Size of 25 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm,1 Run Cable

96*1*0.65

=
=

62

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

10
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

320

1
Vdrop

%Vdrop

4.071
4.071
240

V
x

100

1.7

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

1
Vdrop

%Vdrop

24.428
24.428
240

V
x

100

10.18

192 of 284

320

HZL-BTN-ELE-DS-SY-037
3.03 With in the permissible limit of 15% voltage drop hence ok
It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

25

13.2xt

13.2*.2

4.23

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected
Lime water circulation pumps
1.00 INPUT DATA
1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

320

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 / 0.8

=
3 x V

3 x 0.415x 0.95

Size of 25 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 25 sq.mm,1 Run Cable

96*1*0.65

=
=

62

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

(R cos + X sin)

n
Where,
cos

0.8 (Assumed)

sin

0.6

10
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

1
Vdrop

4.071

V
193 of 284

320

HZL-BTN-ELE-DS-SY-037
%Vdrop

4.071

240

100

1.7

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

320

1
Vdrop

%Vdrop

24.428

24.428

240

100

10.18

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

25

13.2*.2

4.23

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected
NaCN Disinfection Clean Water Pumps
1.00 INPUT DATA
1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

273

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 / 0.8
=

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 0.65
= 70x1x0.65
=

194 of 284

46

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

10
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

273

1
Vdrop

%Vdrop

5.461
5.461

240

100

2.28

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrelcage Motor

60

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

60

1
32.768
32.768

273

V
x

240

((0.00244 x 0.8) + (0.0000808 x 0.6))

100

13.66

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

13.2*.2

KA/0.2Sec

2.71

(Fuse Operated)

1 runs of 1.1kV grade, 3.5C x sq.mm, Al conductor, Armoured, XLPE cable is selected
TAILING THICKENER OVERFLOW PUMPS

1.00 INPUT DATA

1.01 Feeder Load

110

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

360

1.04 AC resistance of the cable at 90C

0.129

1.05 Reactance of the cable at 50Hz

0.0705 / km

/ km

1.06 Allowable Voltage Drop at normal running cond.

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

110 / 0.8
=

3 x V x

=
3 x 0.415x 0.95
195 of 284

201

HZL-BTN-ELE-DS-SY-037
Size of 300 Sq.mm 3.5 core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

300

1.0

455 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 300 sq.mm,2 Run Cable

455*2*0.65

=
=

592 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

(R cos + X sin)

Where,
cos

0.8 (Assumed)

sin

0.6

201
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

360

2
Vdrop

%Vdrop

5.264

5.264

240

100

2.2

3.02 With in the Permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
= 1206 A

DOL or Squirrelcage Motor

( 6 Times the full load current)

Drop at the time of Starting

1206
Vdrop

((0.000129 x 0.8) + (0.0000705 x 0.6))

360

2
Vdrop

%Vdrop

31.585
31.585

240

100

13.17

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

300
13.2*1

22.7

KA/Sec

(ACB Operated)

3.04 2 run of 1.1kV grade, 3.5C x300sq.mm, Al conductor, Armoured, XLPE cable is selected

196 of 284

HZL-BTN-ELE-DS-SY-037
LT CABLE SIZING CALCULATION
CuSo4 Storage Tank Agitator 14
1.00 INPUT DATA
1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

263

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
5.5 / 0.8

P
IFL

=
3 x 0.415x 0.95

3 x V x

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

3 x IFL
n

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

10
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

1
Vdrop

%Vdrop

5.261
5.261
240

V
x

100

2.2

3.02 With in the permissible limits of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

60

( 6 Times the full load current)

197 of 284

263

HZL-BTN-ELE-DS-SY-037
Drop at the time of Starting
60
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

263

1
Vdrop

%Vdrop

31.568
31.568

240

100

13.16

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
SIX Storage Tank Agitator 42

1.00 INPUT DATA

1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

270

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 / 0.98

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 70x1x0.65
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
n

x (R cos + X sin) x
198 of 284

46

HZL-BTN-ELE-DS-SY-037
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

10

1
5.401

((0.00244 x 0.8) + (0.0000808 x 0.6))

270

5.401

240

100

2.26

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

270

1
Vdrop

%Vdrop

32.408

32.408

240

100

13.51

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Nigrosine Mixing Tank Agitator

1.00 INPUT DATA

1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

220

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

P
3 x V x

5.5 / 0.8
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

199 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

10
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

220

1
Vdrop

%Vdrop

4.401

4.401

240

100

1.84

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

220

1
Vdrop

%Vdrop

26.406

26.406

240

100

11.01

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

s
13.2xt

16
13.2*.2

= 2.71

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Nigrosine Storage Tank Agitator

1.00 INPUT DATA

1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

275

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

200 of 284

0.0808 / km

HZL-BTN-ELE-DS-SY-037
1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 / 0.8

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

10
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

275

1
Vdrop

%Vdrop

5.501
5.501
240

V
100

2.3

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

275

1
Vdrop

%Vdrop

33.008
33.008
240

100

13.76

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
201 of 284

HZL-BTN-ELE-DS-SY-037
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Diluted Nigrosine Dosing Tank Agitator

1.00 INPUT DATA

1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

195

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 / 0.8

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 70x1x0.65
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

10

1
V

3.901
3.901
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

100

1.63

3.02 With in the permissible limit of 2.5% voltage drop hence ok

202 of 284

195

HZL-BTN-ELE-DS-SY-037

Check for Starting Current

DOL or Squirrel Cage

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

195

1
Vdrop

%Vdrop

23.406
23.406

240

100

9.76

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Spare Storage Tank Agitator

1.00 INPUT DATA

1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

275

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
5.5 / 0.98

P
IFL

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 0.65
= 70x1x0.65
=

203 of 284

46

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

10
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

275

1
Vdrop

%Vdrop

5.501

5.501

240

100

2.3

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

275

1
Vdrop

%Vdrop

33.008

33.008

240

100

13.76

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

13.2xt

16

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Mill Area spillage pump

1.00 INPUT DATA

1.01 Feeder Load

9.3

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

345

1.04 AC resistance of the cable at 90C

1.11

/ km

1.05 Reactance of the cable at 50Hz

0.0783 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

17

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

9.3 / 0.8
=

3 x V x

=
0.95x3 x 0.415
204 of 284

HZL-BTN-ELE-DS-SY-037

2.02

Size of 35 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 117x1x0.65

2.03 Current carrying capacity of 35 sq.mm1 Run Cable

76

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos
sin
Vdrop

Vdrop

%Vdrop

=
=

0.8 (Assumed)
0.6

17

x ((0.00111 x 1.11) + (0.0000783 x 0.6)) x

345

5.484
5.484

240

100

2.29

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

102

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

102

x ((0.00111 x 0.8) + (0.0000783 x 0.6)) x

1
32.902

345

32.902

240

100

13.71

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

35
13.2*.2

= 5.93

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Regrind Mill Area Spillage Pump
1.00 INPUT DATA
1.01 Feeder Load

9.3

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

295

205 of 284

HZL-BTN-ELE-DS-SY-037
1.04 AC resistance of the cable at 90C

1.05 Reactance of the cable at 50Hz

1.11

/ km

0.0783 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

17

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

3 x V x

9.3 / 0.8

0.95x3 x 0.415

Size of 35 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 35 sq.mm1 Run Cable

= 117*1*0.65
=

76

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

17

Vdrop

Vdrop

%Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

295

1
4.689
4.689
240

V
x

100

1.96

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

102

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

102

x ((0.00111 x 0.8) + (0.0000783 x 0.6)) x

1
28.134
28.134
240

V
x

100

11.73

3.03 With in the permissible limit of 15% voltage drop hence ok

206 of 284

295

HZL-BTN-ELE-DS-SY-037
It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

35

13.2xt

= 5.93

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
Mill Area Spillage Pump
1.00 INPUT DATA
1.01 Feeder Load

9.3

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

240

1.04 AC resistance of the cable at 90C

1.11

/ km

1.05 Reactance of the cable at 50Hz

0.0783 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

17

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

3 x V x

9.3 / 0.8

0.95x3 x 0.415

Size of 35 Sq.mm 3.5core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 35 sq.mm1 Run Cable

= 117*1*0.65
=

76

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

17

1
3.815
3.815
240

((0.00111 x 0.8) + (0.0000783 x 0.6))

V
x

100

1.59

3.02 With in the permissible limit of 2.5% voltage drop hence ok

207 of 284

240

HZL-BTN-ELE-DS-SY-037
Check for Starting Current
DOL or Squirrel Cage

102

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

102

x ((0.00111 x 0.8) + (0.0000783 x 0.6)) x

240

22.888
22.888

240

100

9.54

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Iw

35

13.2xt

= 5.93

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
Cooling Tower
1.00 INPUT DATA
1.01 Feeder Load

9.3

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

50

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

17

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

9.3 / 0.8

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 70x1x0.65
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
n

x (R cos + X sin) x
208 of 284

46

HZL-BTN-ELE-DS-SY-037
Where,
cos

0.8 (Assumed)

sin

0.6

17
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

50

1
Vdrop

%Vdrop

1.7

1.7

240

100

0.71

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

102

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

102

1
10.202

((0.00244 x 0.8) + (0.0000808 x 0.6))

50

10.202

240

100

4.26

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

13.2xt

16

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
VFD - ACS 1000

1.00 INPUT DATA

1.01 Feeder Load

17.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

40

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

32

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

3 x V x

17.5 / 0.8
0.95x3 x 0.415

Size of 16 Sq.mm 4core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

209 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

= 70*1*0.65
46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

32
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

40

1
Vdrop

%Vdrop

2.561

2.561

240

100

1.07

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

192

( 6 Times the full load current)

Drop at the time of Starting

192
Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

40

1
Vdrop

%Vdrop

15.364

15.364

240

100

6.41

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

16
13.2*.2

= 2.71

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Conveyor 08 - pebble recycle conveyor
1.00 INPUT DATA
1.01 Feeder Load

11

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

300

1.04 AC resistance of the cable at 90C

1.11

/ km

1.05 Reactance of the cable at 50Hz

1.06 Allowable Voltage Drop

=
210 of 284

0.0783 / km
2.5

HZL-BTN-ELE-DS-SY-037
1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

20

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

11 / 0.8

=
3 x V x

0.95x3 x 0.415

Size of 35 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 117x1x0.65

2.03 Current carrying capacity of 35 sq.mm Run Cable

76

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

20

Vdrop

Vdrop

%Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

300

1
5.61
5.61
240

V
x

100

2.34

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

120

( 6 Times the full load current)

Drop at the time of Starting

120

Vdrop

Vdrop

%Vdrop

x ((0.00111 x 0.8) + (0.0000783 x 0.6)) x

300

1
33.659
33.659
240

V
x

100

14.03

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
211 of 284

HZL-BTN-ELE-DS-SY-037
Short Time rating of the Cable
Iw

35

13.2xt

= 5.93

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb.CL.3Conc.Return SampleDelivery Pumps
1.00 INPUT DATA
1.01 Feeder Load

11

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

285

1.04 AC resistance of the cable at 90C

1.11

/ km

1.05 Reactance of the cable at 50Hz

0.0783 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

20

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

11 / 0.8

=
3 x 0.415x 0.95

3 x V x
2.02

Size of 35 Sq.mm 3.5 core Aluminium cable is selected for checking.

Rating factor for Ambient
Current Rating at 35C
Cable size
Temperature 35C
35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 35 sq.mm1 Run Cable

117*1*0.65

=
=

76

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

20
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

1
Vdrop

%Vdrop

5.329
5.329
240

V
x

100

2.23

3.02 With in the permissible limit of 2.5% voltage drop hence ok

212 of 284

285

HZL-BTN-ELE-DS-SY-037
Check for Starting Current
DOL or Squirrel Cage

120

( 6 Times the full load current)

Drop at the time of Starting

120
Vdrop

((0.00111 x 0.6) + (0.0000783 x ))

285

1
Vdrop

%Vdrop

22.777

22.777

240

100

9.5

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

Short Time rating of the Cable

Iw

35

13.2xt

= 5.93

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Concentrate thickener area spillage pump No.24
1.00 INPUT DATA
1.01 Feeder Load

11

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

310

1.04 AC resistance of the cable at 90C

1.11

/ km

1.05 Reactance of the cable at 50Hz

0.0783 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

20

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

11 / 0.8

=
3 x V x

=
3 x 0.415x 0.95

Size of 35 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of sq.mm35 Run Cable

= 0.65
117*1*0.65

=
=

213 of 284

76

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

20
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

310

1
Vdrop

%Vdrop

5.797

5.797

240

100

2.42

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

120

( 6 Times the full load current)

Drop at the time of Starting

120
Vdrop

x ((0.00111 x 0.8) + (0.0000783 x 0.6)) x

310

1
Vdrop

%Vdrop

34.781
34.781

240

100

14.5

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

35

13.2xt

13.2*.2

= 5.93

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Concentrate thickener area spillage pump 1
1.00 INPUT DATA
1.01 Feeder Load

11

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

328

1.04 AC resistance of the cable at 90C

0.818

/ km

1.05 Reactance of the cable at 50Hz

0.075

/ km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

20

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

11 / 0.8
=

3 x V x

=
3 x 0.415x 0.95
214 of 284

HZL-BTN-ELE-DS-SY-037
2.02

Size of 50 Sq.mm 3.5 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
50

1.0

142 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 50 sq.mm1 Run Cable

142*1*0.65

92

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

20

1
4.588

((0.000818 x 0.8) + (0.000075 x 0.6))

328

4.588

240

100

1.92

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

120

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

120

((0.000818 x 0.6) + (0.000075 x ))

328

19.318
19.318

240

100

8.05

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

50
13.2*.2

= 8.47

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x50sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Concentrate thickener area spillage pump 2
1.00 INPUT DATA
1.01 Feeder Load

11

kW

1.02 Voltage rating

VT

0.415

kV

215 of 284

HZL-BTN-ELE-DS-SY-037
1.03 Length of the cable

325

1.04 AC resistance of the cable at 90C

0.818

/ km

1.05 Reactance of the cable at 50Hz

0.075

/ km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

20

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

11 / 0.8

3 x V x

3 x 0.415x 0.95

Size of 50 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

50

1.0

142 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 50 sq.mm1 Run Cable

142*1*0.65

=
=

92

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
=

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

20

Vdrop

Vdrop

%Vdrop

((0.000818 x 0.8) + (0.000075 x 0.6))

325

1
4.546
4.546
240

V
x

100

1.9

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

120

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

120

1
19.141

((0.000818 x 0.6) + (0.000075 x ))

V
216 of 284

325

HZL-BTN-ELE-DS-SY-037
%Vdrop

19.141

240

100

7.98

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

50

13.2xt

= 8.47

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x50sq.mm, Al conductor, Armoured, XLPE cable is selected
Conveyor 10 - Zn filter concentrate conveyor
1.00 INPUT DATA
1.01 Feeder Load

11

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

370

1.04 AC resistance of the cable at 90C

0.818

/ km

1.05 Reactance of the cable at 50Hz

0.075

/ km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

20

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

11 / 0.8

3 x V x

3 x 0.415x 0.95

Size of 50 Sq.mm 3.5 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
50

1.0

142 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 50 sq.mm1 Run Cable

142*1*0.65

=
=

92

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

3 x 20

Vdrop

Vdrop

((0.000818 x 0.8) + (0.000075 x 0.6))

1
5.176

V
217 of 284

370

HZL-BTN-ELE-DS-SY-037
%Vdrop

5.176

240

100

2.16

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

120

( 6 Times the full load current)

Drop at the time of Starting

120
Vdrop

((0.000818 x 0.6) + (0.000075 x ))

370

Vdrop

%Vdrop

21.792

21.792

240

100

9.08

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

50

13.2xt

= 8.47

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 3.5C x50sq.mm, Al conductor, Armoured, XLPE cable is selected
Mill Area EOT
1.00 INPUT DATA
1.01 Feeder Load

34.8

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

252

1.04 AC resistance of the cable at 90C

0.323

1.05 Reactance of the cable at 50Hz

0.0712 / km

/ km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

64

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

34.8 / 0.8
=

3 x V x

=
0.95x3 x 0.415

Size of 120 Sq.mm 3.5core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

120

1.0

257 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

218 of 284

HZL-BTN-ELE-DS-SY-037
= 0.65

Total factor to be applied for arriving the capacity

= 257x1x0.65

2.03 Current carrying capacity of 120 sq.mm1 Run Cable

167 A

=
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6

64
Vdrop

((0.000323 x 0.8) + (0.0000712 x 0.6))

252

1
Vdrop

%Vdrop

4.856

4.856

240

100

2.03

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

384

( 6 Times the full load current)

Drop at the time of Starting

384
Vdrop

252

x ((0.000323 x 0.8) + (0.0000712 x 0.6)) x

1

Vdrop

%Vdrop

29.139

29.139

240

100

12.15

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

120
13.2*.2

= 20.3

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 3.5C x120sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Concentrate Thickener - Hydraulic Power Local panel
1.00 INPUT DATA
1.01 Feeder Load

15.87

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

336

1.04 AC resistance of the cable at 90C

1.11

/ km

1.05 Reactance of the cable at 50Hz

0.0783 / km

1.06 Allowable Voltage Drop

1.07 Current derating factors

0.65

219 of 284

HZL-BTN-ELE-DS-SY-037
2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

15.87 / 0.8

3 x V x
2.02

29

3 x 0.415x 0.95

Size of 35 Sq.mm 3.5 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 35 sq.mm1 Run Cable

117*1*0.65

76

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

29
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

336

1
Vdrop

%Vdrop

9.11

9.11

240

100

3.8

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Short Time rating of the Cable
Iw

13.2xt

35
13.2*.2

= 5.93

KA/0.2Sec

(Fuse Operated)

3.03 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn Concentrate Thickener - Hydraulic Power
1.00 INPUT DATA
1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

20

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

220 of 284

HZL-BTN-ELE-DS-SY-037
2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

5.5 / 0.8

3 x V x

3 x 0.415x 0.95

10

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Current Rating at 35C
Cable size
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

70*1*0.65

=
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

10

1
0.4

((0.00244 x 0.8) + (0.0000808 x 0.6))

20

0.4

240

100

0.17

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

60

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

60

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

1
2.401

20

2.401

240

100

1.01

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

16
13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
221 of 284

HZL-BTN-ELE-DS-SY-037
Screw Feeder
1.00 INPUT DATA
1.01 Feeder Load

0.37

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

20

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

3 x V x

0.37 / 0.8

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

70*1*0.65

=
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
1

1
0.04
0.04
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

20

V
x

100

0.02

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

6
1

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

222 of 284

20

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

0.24

0.24

240

100

0.1

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Agitator in mixing tank
1.00 INPUT DATA
1.01 Feeder Load

1.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

20

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
1.5 /0.8

P
IFL

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

70*1*0.65

=
=

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x
n

Where,
cos

0.8 (Assumed)

sin

0.6
223 of 284

46

HZL-BTN-ELE-DS-SY-037
3

Vdrop

Vdrop

%Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

20

1
0.12

0.12

240

100

0.05

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

18

( 6 Times the full load current)

Drop at the time of Starting

18
Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

20

Vdrop

%Vdrop

0.72

0.72

240

100

0.3

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

16

13.2xt

13.2*.2

= 2.71

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Transfer Pumps
1.00 INPUT DATA
1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

20

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

5.5 /0.8

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

224 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

70*1*0.65

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

10
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

20

1
Vdrop

%Vdrop

0.4

0.4

240

100

0.17

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

20

1
Vdrop

%Vdrop

2.401

2.401

240

100

1.01

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

16
13.2*.2

= 2.71

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Flocculant dosing pumps
1.00 INPUT DATA
1.01 Feeder Load

1.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

20

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

1.06 Allowable Voltage Drop

=
225 of 284

/ km

0.0808 / km
2.5

HZL-BTN-ELE-DS-SY-037
1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

1.5 /0.8
=

=
3 x V x

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

70*1*0.65

=
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
3

Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

20

1
Vdrop

%Vdrop

0.12
0.12
240

100

0.05

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

18

( 6 Times the full load current)

Drop at the time of Starting

18
Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

20

1
Vdrop

%Vdrop

0.72
0.72
240

100

0.3

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
226 of 284

HZL-BTN-ELE-DS-SY-037
Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
MCC TO TAILING THICKENER
1.00 INPUT DATA
1.01 Feeder Load

16.37

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

330

1.04 AC resistance of the cable at 90C

1.11

/ km

1.05 Reactance of the cable at 50Hz

0.0783 / km

1.06 Allowable Voltage Drop

1.07 Current derating factors

0.65

28

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

16.37 / 0.8

3 x V

3 x 0.415

Size of 35 Sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

35

1.0

117 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 35 sq.mm1 Run Cable

117*1*0.65

=
=

76

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

28
Vdrop

((0.00111 x 0.8) + (0.0000783 x 0.6))

1
Vdrop

%Vdrop

8.639
8.639
240

100

3.6

3.02 With in the permissible limit of 5% voltage drop hence ok

227 of 284

330

HZL-BTN-ELE-DS-SY-037
Short Time rating of the Cable
Iw

35

13.2xt

= 5.93

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.03 1 run of 1.1kV grade, 3.5C x35sq.mm, Al conductor, Armoured, XLPE cable is selected
LOCAL PANEL TO TAILING THICKENER
1.00 INPUT DATA
1.01 Feeder Load

7.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

20

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

14

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

7.5 / 0.8

=
3 x V x

2.02

=
3 x 0.415x 0.95

Size of 16 sq.mm3.5 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of16sq.mm, 1 Run Cable

70*1*0.65

=
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

14
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

1
Vdrop

%Vdrop

0.56
0.56
240

100

0.24

3.02 With in the permissible limit of 2.5% voltage drop hence ok

228 of 284

20

HZL-BTN-ELE-DS-SY-037

Check for Starting Current

DOL or Squirrel Cage

84

( 6 Times the full load current)

Drop at the time of Starting

84
Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

20

1
Vdrop

%Vdrop

3.361

3.361

240

100

1.41

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Screw Feeder
1.00 INPUT DATA
1.01 Feeder Load

0.37

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

20

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

0.37 / 0.8
=

3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm,1 Run Cable

= 0.65
70*1*0.65

=
=

229 of 284

46

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
1

1
0.04

((0.00244 x 0.8) + (0.0000808 x 0.6))

20

0.04

240

100

0.02

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

20

0.24
0.24

240

100

0.1

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

16

13.2xt

13.2*.2

= 2.71

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Agitator in mixing tank
1.00 INPUT DATA
1.01 Feeder Load

1.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

20

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

1.5 / 0.8
=

3 x V x

=
3 x 0.415x 0.95
230 of 284

HZL-BTN-ELE-DS-SY-037
Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm,1 Run Cable

70*1*0.65

=
=

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL

Vdrop

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
2

Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

20

1
Vdrop

%Vdrop

0.08

0.08

240

100

0.04

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

12

( 6 Times the full load current)

Drop at the time of Starting

12
Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

20

1
Vdrop

%Vdrop

0.48

0.48

240

100

0.2

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

16
13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected

231 of 284

HZL-BTN-ELE-DS-SY-037
Transfer Pumps
1.00 INPUT DATA
1.01 Feeder Load

5.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

20

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

10

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

3 x V x

5.5 / 0.8

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 25 sq.mm,1 Run Cable

70*1*0.65

=
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6

10

1
0.4
0.4
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

20

V
x

100

0.17

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

60

( 6 Times the full load current)

Drop at the time of Starting

60
Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

1
232 of 284

20

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

2.401

2.401

240

100

1.01

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

16

13.2xt

KA/0.2Sec

= 2.71

13.2*.2

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Flocculant dosing pumps
1.00 INPUT DATA
1.01 Feeder Load

1.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

20

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

1.5 / 0.8

=
3 x 0.415x 0.95

3 x V x

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm,1 Run Cable

70*1*0.65

=
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
233 of 284

46

HZL-BTN-ELE-DS-SY-037
3
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

20

1
Vdrop

%Vdrop

0.12

0.12

240

100

0.05

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

18

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

18

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

20

0.72
0.72

240

100

0.3

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Belt Magnet (Self Cleaning) Conveyor 06 - Belt Drive
1.00 INPUT DATA
1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

325

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

P
3 x V x

3.7 / 0.8
0.95x3 x 0.415

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

234 of 284

HZL-BTN-ELE-DS-SY-037
Factor for Non linear loads

0.8

= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
7

1
4.551

((0.00244 x 0.8) + (0.0000808 x 0.6))

325

4.551

240

100

1.9

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

42
Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

325

Vdrop

%Vdrop

27.307

27.307

240

100

11.38

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

16
13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Water Pump in B03 - FMC - 110
1.00 INPUT DATA
1.01 Feeder Load

3.72

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

232

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

235 of 284

HZL-BTN-ELE-DS-SY-037
1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

3.72 / 0.8

3 x V x

0.95x3 x 0.415

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6
7

Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

232

1
Vdrop

%Vdrop

3.249
3.249
240

100

1.36

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

42
Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

232

1
Vdrop

%Vdrop

19.493
19.493
240

V
x

100

8.13

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
236 of 284

HZL-BTN-ELE-DS-SY-037
Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Self cleaning belt magnet - Conveyor 08 (Belt drive)
1.00 INPUT DATA
1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

20

1.04 AC resistance of the cable at 90C

2.44

1.05 Reactance of the cable at 50Hz

/ km

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

3 x V x

3.7 / 0.8

0.95x3 x 0.415

Size of 16 Sq.mm 4core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

sin

0.8 (Assumed)
0.6
7

1
0.28
0.28
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

V
x

100

0.12

3.02 With in the permissible limit of 2.5% voltage drop hence ok

237 of 284

20

HZL-BTN-ELE-DS-SY-037

Check for Starting Current

DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

42
Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

20

1
Vdrop

%Vdrop

1.68
1.68

240

100

0.7

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Servo Motor/Circulating Motor
1.00 INPUT DATA
1.01 Feeder Load

0.5

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

275

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

0.5 / 0.8
=

3 x V x

=
0.95x3 x 0.415

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

= 0.65
= 70x1x0.65
=

238 of 284

46

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
1

1
0.55

((0.00244 x 0.8) + (0.0000808 x 0.6))

275

0.55

240

100

0.23

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

1
3.301

275

3.301

240

100

1.38

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

13.2xt

16

13.2*.2

= 2.71

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb.Multistream Analysis
1.00 INPUT DATA
1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

245

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

3.7 / 0.8
=

3 x V

=
3 x 0.415
239 of 284

HZL-BTN-ELE-DS-SY-037

2.02

Size of 16 Sq.mm 4core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
6

1
2.941

((0.00244 x 0.8) + (0.0000808 x 0.6))

245

2.941

240

100

1.23

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

36

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

36

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

245

17.644
17.644

240

100

7.36

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

16
13.2*.2

= 2.71

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Zn.Multistream Analysis
1.00 INPUT DATA
1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

240 of 284

HZL-BTN-ELE-DS-SY-037
1.03 Length of the cable

245

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

3.7 / 0.8

3 x V

3 x 0.415

Size of 16 Sq.mm 4core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
6

1
2.941

((0.00244 x 0.8) + (0.0000808 x 0.6))

245

2.941

240

100

1.23

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Short Time rating of the Cable
Iw

13.2xt

16
13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Concentrate Thickener - Hydraulic Power Pack
1.00 INPUT DATA
1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

213

241 of 284

HZL-BTN-ELE-DS-SY-037
1.04 AC resistance of the cable at 90C

1.05 Reactance of the cable at 50Hz

2.44

/ km

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder

P
IFL

3.7 / 0.8

=
3 x V x

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

70*1*0.65

=
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
=

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
7

Vdrop

Vdrop

2.983

%Vdrop

2.983
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

213

V
x

100

1.25

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
42
DOL or Squirrel Cage
=
A ( 6 Times the full load current)
Drop at the time of Starting
Vdrop

Vdrop

%Vdrop

42

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

1
17.896
17.896
240

V
x

100

7.46

3.03 With in the permissible limit of 15% voltage drop hence ok

242 of 284

213

HZL-BTN-ELE-DS-SY-037
It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb Filter cloth wash water pumps
1.00 INPUT DATA
1.01 Feeder Load

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

370

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

3 x V x

4 / 0.8

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Current Rating at 35C
Cable size
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

= 70*1*0.65
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos
sin

=
=

0.8 (Assumed)
0.6
7

Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

1
Vdrop

5.181

%Vdrop

5.181
240

V
x

100

2.16

243 of 284

370

HZL-BTN-ELE-DS-SY-037
3.02 With in the permissible limit of 2.5% voltage drop hence ok
Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

1
31.087

370

31.087

240

100

12.96

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Gland Seale Water Pumps For Pb & Zn Filter Pumps
1.00 INPUT DATA
1.01 Feeder Load

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

240

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

4 / 0.8

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

= 0.65
70*1*0.65

=
=

244 of 284

46

HZL-BTN-ELE-DS-SY-037
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
7

Vdrop

Vdrop

%Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

240

1
3.361

3.361

240

100

1.41

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

42
Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

240

1
Vdrop

%Vdrop

20.165

20.165

240

100

8.41

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

13.2xt

16

13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Oil Cooler (Air)
1.00 INPUT DATA
1.01 Feeder Load

0.75

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

330

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

0.75 / 0.8
=

3 x V

=
3 x 0.415
245 of 284

HZL-BTN-ELE-DS-SY-037
Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

70*1*0.65

=
=

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6
1

Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

330

1
Vdrop

%Vdrop

0.66

0.66

240

100

0.28

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

( 6 Times the full load current)

Drop at the time of Starting

6
Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

330

1
Vdrop

%Vdrop

3.961
3.961

240

100

1.66

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

16
13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected

246 of 284

HZL-BTN-ELE-DS-SY-037
Conveyor 11 tripper car
1.00 INPUT DATA
1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

430

1.04 AC resistance of the cable at 90C

1.53

/ km

1.05 Reactance of the cable at 50Hz

0.0805 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

3.7 / 0.8

3 x V x

3 x 0.415x 0.95

Size of 25 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

25

1.0

96 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 25 sq.mm1 Run Cable

96*1*0.65

=
=

62

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
=

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

7
Vdrop

((0.00153 x 0.8) + (0.0000805 x 0.6))

430

1
Vdrop

%Vdrop

3.83
3.83
240

V
x

100

1.6

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42
247 of 284

( 6 Times the full load current)

HZL-BTN-ELE-DS-SY-037
Drop at the time of Starting
42
Vdrop

x ((0.00153 x 0.8) + (0.0000805 x 0.6)) x

430

1
Vdrop

%Vdrop

22.978

22.978

100

240

9.58

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

25

13.2xt

= 4.23

13.2*.2

(Fuse Operated)

KA/0.2Sec

3.04 1 run of 1.1kV grade, 4C x25sq.mm, Al conductor, Armoured, XLPE cable is selected
Lime Mixing tank Agitator
1.00 INPUT DATA
1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

320

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
3.7 / 0.8

P
IFL

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16sq.mm,1 Run Cable

70*1*0.65

=
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
n

x (R cos + X sin) x
248 of 284

46

HZL-BTN-ELE-DS-SY-037
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
7

((0.00244 x 0.8) + (0.0000808 x 0.6))

320

4.481
4.481

240

100

1.87

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

1
26.886

320

26.886

100

240

11.21

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
Air Dryer
1.00 INPUT DATA
1.01 Feeder Load

2.2

kW

1.04 Voltage rating

VT

0.415

kV

1.03 Length of the cable

320

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

P
3 x V x

2.2 / 0.8
3 x 0.415x 0.95

Size of 16 sq.mm 3.5 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

249 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16 sq.mm 1Run cable

70*1*0.65

=
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
4

((0.00244 x 0.8) + (0.0000808 x 0.6))

320

2.561
2.561

100

240

1.07

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

24

( 6 Times the full load current)

Drop at the time of Starting

24

Vdrop

Vdrop

%Vdrop

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

320

1
15.364

15.364

240

100

6.41

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.03

s
13.2xt

16

13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
CuSo4 Mixing Tank Agitator 06

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

240

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

1.06 Allowable Voltage Drop

=
250 of 284

0.0808 / km
2.5

HZL-BTN-ELE-DS-SY-037
1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

3.7 / 0.8

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
=

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
7

Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

240

1
Vdrop

%Vdrop

3.361
3.361
240

V
=

100

1.41

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

42
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

240

1
Vdrop

%Vdrop

20.165
20.165
240

V
x

100

8.41

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
251 of 284

HZL-BTN-ELE-DS-SY-037
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
CuSo4 Transfer Pumps 16

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

371

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

3.7 / 0.8

=
3 x V x

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm1,Run cable

= 70x1x0.65
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

3 x IFL
n

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
7

1
V

5.195
5.195
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

100

2.17

3.02 With in the permissible limit of 2.5% voltage drop hence ok

252 of 284

371

HZL-BTN-ELE-DS-SY-037
Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

((0.371 x 0.8) + (0.00244 x 0.6))

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42
1

371

31.171
31.171

100

240

12.99

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
CuSo4 Unloading pumps

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

213

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

P
3 x V x

3.7 / 0.8
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm1,Run cable

= 70x1x0.65
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

3 x IFL
n

x (R cos + X sin) x
253 of 284

46

HZL-BTN-ELE-DS-SY-037
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
7

1
2.983

((0.00244 x 0.8) + (0.0000808 x 0.6))

213

2.983

100

240

1.25

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42

((0.00244 x 0.8) + (0.0000808 x 0.6))

213

17.896
17.896

240

100

7.46

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Cuso4 Centrifugal Pumps

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

215

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

P
3 x V x

3.7 / 0.8
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Current Rating at 35C
Cable size
Temperature 35C
16

70 A

1.0

(Ref : Power Engineers Handbook 25.66, Table 57)

254 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x

n
Where,
cos

0.8 (Assumed)

sin

0.6
7

Vdrop

Vdrop

%Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

215

1
V

3.011
3.011

240

100

1.26

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

42
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

215

1
Vdrop

%Vdrop

26.729
26.729

240

100

11.14

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

Short Time rating of the Cable

Iw
3.04

s
13.2xt

16
13.2*.2

KA/0.2Sec

= 2.71

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
SIX Transfer pumps

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

225

255 of 284

HZL-BTN-ELE-DS-SY-037
1.04 AC resistance of the cable at 90C

1.05 Reactance of the cable at 50Hz

2.44

/ km

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

3.7 / 0.8

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
7

1
3.151
3.151
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

225

V
x

100

1.32

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42

1
18.905
18.905
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

V
x

100

7.88

3.03 With in the permissible limit of 15% voltage drop hence ok

256 of 284

225

HZL-BTN-ELE-DS-SY-037
It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
SIX Centrifugal pumps

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

228

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

3 x V

3.7 / 0.8

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 70x1x0.65
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
7

1
3.193
3.193
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

V
x

100

1.34

3.02 With in the permissible limit of 2.5% voltage drop hence ok

257 of 284

228

HZL-BTN-ELE-DS-SY-037
Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42

((0.00244 x 0.8) + (0.0000808 x 0.6))

3.7

19.157
19.157

240

100

7.99

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

(Fuse Operated)

KA/0.2Sec

= 2.71

13.2*.2

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Pex Transfer Pumps

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

210

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

3 x V x

3.7 / 0.8
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 70x1x0.65
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

3 x IFL
n

x (R cos + X sin) x
258 of 284

46

HZL-BTN-ELE-DS-SY-037
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
7

1
2.941

((0.00244 x 0.8) + (0.0000808 x 0.6))

210

2.941

240

100

1.23

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42

1
17.644

((0.00244 x 0.8) + (0.0000808 x 0.6))

3.7

17.644

240

100

7.36

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Pex Centrifugal Pumps

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

211

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

P
3 x V x

3.7 / 0.8
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

259 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
7

Vdrop

Vdrop

%Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

211

1
2.955

2.955

240

100

1.24

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current

DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

42
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

211

1
Vdrop

%Vdrop

17.728

17.728

240

100

7.39

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

Short Time rating of the Cable

Iw
3.04

s
13.2xt

16
13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Nigrosine Transfer Pumps

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

202

1.04 AC resistance of the cable at 90C

2.44

/ km

260 of 284

HZL-BTN-ELE-DS-SY-037
1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

3 x V x

3.7 / 0.8

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
7

1
2.829
2.829
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

202

V
x

100

1.18

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42

1
16.972
16.972
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

202

V
x

100

7.08

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
261 of 284

HZL-BTN-ELE-DS-SY-037
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Nigrosine Centrifugal Pumps (3% solution)

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

202

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
3.7 / 0.8

P
IFL

=
3 x V x

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 70x1x0.65
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
7

1
2.829
2.829
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

V
x

100

1.18

3.02 With in the permissible limit of 2.5% voltage drop hence ok

262 of 284

202

HZL-BTN-ELE-DS-SY-037
Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42

1
16.972

((0.00244 x 0.8) + (0.0000808 x 0.6))

202

16.972

240

100

7.08

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Diluted Nigrosine Centrifugal Pump(0.25% solution)

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

190

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

P
3 x V x

3.7 / 0.8
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 70x1x0.65
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
n

x (R cos + X sin) x
263 of 284

46

HZL-BTN-ELE-DS-SY-037
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
7

1
2.661

((0.00244 x 0.8) + (0.0000808 x 0.6))

190

2.661

240

100

1.11

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42

1
15.964

((0.00244 x 0.8) + (0.0000808 x 0.6))

190

15.964

240

100

6.66

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
MIBC metering pump

1.00 INPUT DATA

1.01 Feeder Load

0.37

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

202

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

P
3 x V x

0.37 / 0.8
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

264 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
IFL

Vdrop

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
1

Vdrop

Vdrop

%Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

202

1
0.404

0.404

240

100

0.17

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

( 6 Times the full load current)

Drop at the time of Starting

6
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

202

1
Vdrop

%Vdrop

2.425

2.425

240

100

1.02

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage

Short Time rating of the Cable

Iw
3.04

s
13.2xt

16
13.2*.2

= 2.71

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
NaCN transfer pumps

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

230

1.04 AC resistance of the cable at 90C

2.44

/ km

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HZL-BTN-ELE-DS-SY-037
1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

3.7 / 0.8

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
=

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
7

Vdrop

Vdrop

%Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

230

1
V

3.221
3.221
240

100

1.35

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42

1
19.325
19.325
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

V
x

100

8.06

3.03 With in the permissible limit of 15% voltage drop hence ok

266 of 284

230

HZL-BTN-ELE-DS-SY-037
It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

KA/0.2Sec

= 2.71

13.2*.2

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
NaCN Centrifugal pumps

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

175

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

3 x V x

3.7 / 0.8

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 70x1x0.65
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
7

1
V

2.451
2.451
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

100

1.03

3.02 With in the permissible limit of 2.5% voltage drop hence ok

267 of 284

175

HZL-BTN-ELE-DS-SY-037
Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42

1
14.704

((0.00244 x 0.8) + (0.0000808 x 0.6))

175

14.704

240

100

6.13

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Spare Transfer Pumps

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

210

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

P
3 x V x

3.7 / 0.8
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 70x1x0.65
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
=

x (R cos + X sin) x
n
268 of 284

46

HZL-BTN-ELE-DS-SY-037
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
7

1
2.941

((0.00244 x 0.8) + (0.0000808 x 0.6))

210

2.941

240

100

1.23

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42

1
17.644

((0.00244 x 0.8) + (0.0000808 x 0.6))

210

17.644

240

100

7.36

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Spare Centrifugal Pumps

1.00 INPUT DATA

1.01 Feeder Load

3.7

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

206

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

P
3 x V x

3.7 / 0.8
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

269 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
7

Vdrop

Vdrop

%Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

206

1
2.885

2.885

240

100

1.21

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42

1
17.308

((0.00244 x 0.8) + (0.0000808 x 0.6))

206

17.308

240

100

7.22

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

s
13.2xt

16
13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Pb filter Manifold wash water pumps

1.00 INPUT DATA

1.01 Feeder Load

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

368

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

270 of 284

HZL-BTN-ELE-DS-SY-037
1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

4 / 0.8

3 x V

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

70*1*0.65

=
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
7

1
5.153

((0.00244 x 0.8) + (0.0000808 x 0.6))

368

5.153

240

100

2.15

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

42

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

Vdrop

%Vdrop

42

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

368

30.919
30.919

240

100

12.89

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

s
13.2xt

16
13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
271 of 284

HZL-BTN-ELE-DS-SY-037
Sealing water Pump for Pb. Filter feed pump No.70
1.00 INPUT DATA
1.01 Feeder Load

0.37

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

305

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

2.02

3 x V

0.37 / 0.8

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 16 sq.mm1 Run Cable

70*1*0.65

=
=

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
1

1
0.61
0.61
240

((0.00244 x 0.8) + (0.0000808 x 0.6))

305

V
x

100

0.26

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

( 6 Times the full load current)

Drop at the time of Starting

Vdrop

6
1

x ((0.00244 x 0.8) + (0.0000808 x 0.6)) x

272 of 284

305

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

3.661

3.661

240

100

1.53

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw

16

13.2xt

= 2.71

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.04 1 run of 1.1kV grade, 4C x16sq.mm, Al conductor, Armoured, XLPE cable is selected
GSS TO MPP MLDB
1.00 INPUT DATA
1.01 Feeder Load

100

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

500

1.04 AC resistance of the cable at 90C

0.161

/ km

1.05 Reactance of the cable at 50Hz

0.071

/ km

1.06 Allowable Voltage Drop

1.07 Current derating factors

0.65

kVA

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

100

2.02

139

3 x V

3 x 0.415

Size of 240 Sq.mm 3.5 core Aluminium cable is selected for checking.
Rating factor for Ambient
Cable size
Current Rating at 35C
Temperature 35C
240

1.0

399 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non linear loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 Current carrying capacity of 240 sq.mm1 Run Cable

399*1*0.65

=
=

259 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6

139
Vdrop

((0.000161 x 0.8) + (0.000071 x 0.6))

1
273 of 284

500

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

11.912

11.912

240

100

4.97

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Short Time rating of the Cable
Iw

240

13.2xt

= 40.7

13.2*.2

KA/0.2Sec

(Fuse Operated)

3.03 1 run of 1.1kV grade, 3.5C x240sq.mm, Al conductor, Armoured, XLPE cable is selected
PMCC TO MCC INCOMER
1.00 INPUT DATA
1.01 Feeder Load

460

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

50

1.04 AC resistance of the cable at 90C

0.129

1.05 Reactance of the cable at 50Hz

0.0705 / km

1.06 Allowable Voltage Drop

1.07 Current derating factor

0.65

/ km
%

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

3 x V

460 / 0.8

3 x 0.415

800

Size of 300 Sq.mm 3.5 core Aluminium cable is selected for checking.
2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

300

1.0

455 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving at the capacity

= 455x3x0.65

2.03 current carrying capacity of 300sq.mm,3Run cable

887 A

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

cos

0.8 (Assumed)

sin

0.6

800
=

((0.000129 x 0.8) + (0.0000705 x 0.6))

3
274 of 284

50

HZL-BTN-ELE-DS-SY-037
Vdrop

%Vdrop

1.94

1.94

240

100

0.81

With in the permissible limits of 5% voltage drop hence ok

3.02 Short Time rating of the Cable
Iw
3.03

300

13.2xt

= 22.7

13.2*1

KA/1Sec

(ACB Operated)

3 runs of 1.1kV grade, 3.5C x300 sq.mm, Al conductor, Armoured, XLPE cable is selected
LIGHTING TRANSFORMER TO MLDB

1.00 INPUT DATA

1.01 Feeder Load

500

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

40

1.04 AC resistance of the cable at 90C

0.161

/ km

1.05 Reactance of the cable at 50Hz

0.071

/ km

1.06 Allowable Voltage Drop

2.5

1.07 Current derating factors

0.65

KVA

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

500

3 x V

696

3 x 0.415

Size of 240 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

240

1.0

399 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 399x3x0.65

2.03 current carrying capacity of 240sq.mm,3Run cable

=
3.00 Check for voltage drop
3.01 Voltage drop
IFL
Vdrop

x (R cos + X sin) x
n

Where,
cos

0.8 (Assumed)
275 of 284

778 A

HZL-BTN-ELE-DS-SY-037
sin

0.6

696
Vdrop

((0.000161 x 0.8) + (0.000071 x 0.6))

40

3
Vdrop

%Vdrop

1.591

1.591

100

240

0.67

With in the permissible limit of 2.5% voltage drop hence ok

3.02 Short Time rating of the Cable
Iw
3.03

240

13.2xt

= 40.7

13.2*.2

(Fuse Operated)

KA/0.2Sec

3 runs of 1.1kV grade, 3.5C x240 sq.mm, Al conductor, Armoured, XLPE cable is selected

PMCC TO AUX. SWITCH BOARD

1.00 INPUT DATA
1.01 Feeder Load

230

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

50

1.04 AC resistance of the cable at 90C

0.21

1.05 Reactance of the cable at 50Hz

/ km

0.0718 / km

1.06 Allowable Voltage Drop

2.5

1.07 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
IFL

3 x V

230 / 0.8

3 x 0.415

400

Size of 185 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

185

1.0

337 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 337x2x0.65

2.03 current carrying capacity of 185sq.mm,2Run cable

=
3.00 Check for voltage drop
3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
276 of 284

438 A

HZL-BTN-ELE-DS-SY-037
Vdrop

Vdrop

%Vdrop

400

((0.00021 x 0.8) + (0.0000718 x 0.6))

50

2.111
2.111

240

100

0.88

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Short Time rating of the Cable
Iw
3.03

185

13.2xt

= 31.3

13.2*.2

KA/0.2Sec

2 runs of 1.1kV grade, 3.5C x185 sq.mm, Al conductor, Armoured, XLPE cable is selected
SIX MixingTank Agitator

1.00 INPUT DATA

1.01 Feeder Load

2.2

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

270

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
2.2 / 0.98

P
IFL

=
3 x V x

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 70x1x0.65
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
277 of 284

46

HZL-BTN-ELE-DS-SY-037

Vdrop

Vdrop

%Vdrop

1
2.161

((0.00244 x 0.8) + (0.0000808 x 0.6))

270

2.161

240

100

0.91

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

24

( 6 Times the full load current)

Drop at the time of Starting

24
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

270

1
Vdrop

%Vdrop

12.963

12.963

240

100

5.41

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Pex MixingTank Agitator

1.00 INPUT DATA

1.01 Feeder Load

2.2

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

211

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
2.2 / 0.98

P
IFL

=
3 x V x

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86
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HZL-BTN-ELE-DS-SY-037
Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
4

1
1.688

((0.00244 x 0.8) + (0.0000808 x 0.6))

211

1.688

240

100

0.71

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

24

( 6 Times the full load current)

Drop at the time of Starting

24
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

211

1
Vdrop

%Vdrop

10.13

10.13

240

100

4.23

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

s
13.2xt

16

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Pex Storage Tank Agitator

1.00 INPUT DATA

1.01 Feeder Load

2.2

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

211

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

279 of 284

HZL-BTN-ELE-DS-SY-037
2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

2.2 / 0.98

=
3 x V x

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
4

1
1.688

((0.00244 x 0.8) + (0.0000808 x 0.6))

211

1.688

240

100

0.71

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

24

( 6 Times the full load current)

Drop at the time of Starting

24
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

211

1
Vdrop

%Vdrop

10.13
10.13

240

100

4.23

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

s
13.2xt

16
13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
280 of 284

HZL-BTN-ELE-DS-SY-037
Nacn Mixing tank Agitator
1.00 INPUT DATA
1.01 Feeder Load

1.1

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

230

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
1.1 / 0.98

P
IFL

=
3 x V x

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,
cos

0.8 (Assumed)

sin

0.6
2

Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

1
Vdrop

%Vdrop

0.92
0.92
240

V
x

100

0.39

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

12

( 6 Times the full load current)

281 of 284

230

HZL-BTN-ELE-DS-SY-037
Drop at the time of Starting
12
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

230

1
Vdrop

%Vdrop

5.521

5.521

240

100

2.31

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

= 2.71

13.2*.2

(Fuse Operated)

KA/0.2Sec

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Nacn Storage Tank Agitator

1.00 INPUT DATA

1.01 Feeder Load

2.2

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

230

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
P
IFL

2.2 / 0.98

=
3 x V x

3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

2.03 current carrying capacity of 16sq.mm,1Run cable

= 70x1x0.65
=

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL
n

x (R cos + X sin) x

282 of 284

46

HZL-BTN-ELE-DS-SY-037
Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
4

1
1.84

((0.00244 x 0.8) + (0.0000808 x 0.6))

230

1.84

240

100

0.77

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

24

( 6 Times the full load current)

Drop at the time of Starting

24
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

230

1
Vdrop

%Vdrop

11.043
11.043

240

100

4.61

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

16

13.2xt

KA/0.2Sec

= 2.71

13.2*.2

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected
Spare Mixing Tank Agitator

1.00 INPUT DATA

1.01 Feeder Load

2.2

kW

1.02 Voltage rating

VT

0.415

kV

1.03 Length of the cable

275

1.04 AC resistance of the cable at 90C

2.44

/ km

1.05 Reactance of the cable at 50Hz

0.0808 / km

1.06 Allowable Voltage Drop

2.5

1.07 Allowable Voltage Drop at Starting Condition

15

1.08 Current derating factors

0.65

2.00 Calculation
2.01 Full load current rating of the Feeder
2.2 / 0.98

P
IFL

=
3 x V x

=
3 x 0.415x 0.95

Size of 16 Sq.mm 4 core Aluminium cable is selected for checking.

2.02

Cable size

Rating factor for Ambient

Temperature 35C

Current Rating at 35C

16

1.0

70 A

(Ref : Power Engineers Handbook 25.66, Table 57)

283 of 284

HZL-BTN-ELE-DS-SY-037
Factor for grouping of cables

= 0.86

Reduction Factor

0.9

Factor for Non leaner loads

0.8
= 0.65

Total factor to be applied for arriving the capacity

= 70x1x0.65

2.03 current carrying capacity of 16sq.mm,1Run cable

46

3.00 Check for voltage drop

3.01 Voltage drop
Vdrop

IFL

x (R cos + X sin) x

Where,

Vdrop

Vdrop

%Vdrop

cos

0.8 (Assumed)

sin

0.6
4

1
2.201

((0.00244 x 0.8) + (0.0000808 x 0.6))

275

2.201

240

100

0.92

3.02 With in the permissible limit of 2.5% voltage drop hence ok

Check for Starting Current
DOL or Squirrel Cage

24

( 6 Times the full load current)

Drop at the time of Starting

24
Vdrop

((0.00244 x 0.8) + (0.0000808 x 0.6))

275

1
Vdrop

%Vdrop

13.203

13.203

240

100

5.51

3.03 With in the permissible limit of 15% voltage drop hence ok

It is to be noted that motor has been selected to start upto 80% of rated voltage
Short Time rating of the Cable
Iw
3.04

s
13.2xt

16
13.2*.2

= 2.71

KA/0.2Sec

(Fuse Operated)

1 runs of 1.1kV grade, 4C x16 sq.mm, Al conductor, Armoured, XLPE cable is selected

284 of 284