PROJECT : OIL WATER SEPARATOR- 150 kL/Hr

CLIENT : M/S IOCL, AGARTALA

CONSULTANT : M/S DEVELOPMENT CONSULTANT PRIVATE LTD

EPC : M/S MK ROY & BROS PROJECTS [Link].

VENDOR : M/S PURE TECH INDIA

CLIENT CODE : CC1428

DOC. NAME : Main cable sizing & Cable schedule

DOC. NUMBER : PTI_CC1428_E08

REV No & Date : 02 & 16.05.2025

An ISO 9001:2015 Certified company

 Main Incoming Power Cable Sizing calculation

OWS system working loads are,

Skimmer Pump : 0.75 kW

Belt skimmer-1 : 0. 375 kW

Belt skimmer-2 : 0. 375 kW

Feed pump : 22.0 kW

Oil transfer pump : 0.75 kW

Sludge pump : 1.50 kW

Treated water transfer pump : 22.0 kW

MAX. WORKING LOAD : 47.75

kW

Power Factor, cos ϕ : 0.8

System voltage, V1 : 415 V

Cable length ,L : 550

Mtrs Calculation part,

Full load Current = Power / (1.732*V*PF)

= (47.75*1000) / (1.732*415*0.8)
Full Load Current, I = 83 Ampere

This is the full load current, the cable needs to withstand in OWS running condition.

But in a practical situation, there are some derating factors which need to be considered.

We have assumed/taken the following cable correction factors

1. Temperature correction factor, K1 = 0.87 (Considered 450 temp.)

2. Ground temperature factor, K2 = 0.80 (Considered 450 temp.)

3. Soil correction factor, K3 = 1.05 (Considered damp soil)

4. Cable depth correction factor, K4 = 1.1 (Considered 0.5-meter laying depth)

Total derating factor, K = K1*K2*K3*K4

= 0.87*0.80*1.05*1.1

K = 0.8
 We have considered 1.1kV, 3.5 Core, 185 [Link] Aluminium XLPE Armoured cable

Current carrying capacity of 185 [Link] cable is 285 Amp

Total derating current of 185 [Link] cable = 0.8*285

Total derating current = 228 Amp

Cable Resistance, R = 0.211 ohm/km

Cable Reactance, X = 0.0718 ohm/km

Voltage drop = [1.732*I* (R*cos ϕ + X*sin ϕ) * L] / 1000

= [1.732*83*(0.211*0.8 + 0.0718*0.6) *550] / 1000

= 16752 / 1000 volts

Voltage drop = 17 volts

% Voltage drop = (Voltage drop / V1) * 100

= (17 / 415) * 100

% Voltage drop = 4.0%

RESULT:

1. Cable derating amp (228 A) is higher than the full load current (83 A) = SAFE

2. Cable voltage drop (4%) is lesser than the acceptable voltage drops (5%) = SAFE

STARTING VOLTAGE DROP CALCULATION:

Full Load Current:
22.00 kW Motor FLC = 22000 / (1.732 × 415 × 0.8) = 38.26 A
0.75 kW FLC = 750 / (1.732 × 415 × 0.8) = 1.30 A
0.375 kW FLC = 0.65 A
1.5 kW FLC = 2.60 A
Starting Current:
considered 8.4 times for starting current.
Star-Delta Motors:
2 × (38.26 A × 8.4 / 3) = 2 × 107.13 = 214.25 A
DOL Motors:
(0.75 + 0.375 + 0.375 + 0.75 + 1.5) kW
= 3.75 kW
FLC of 3.75 kW = 3750 / (1.732 × 415 × 0.8) = 6.52 A
DOL Starting Current = 6.52 × 8.4 = 54.78 A
Total Starting Current = 214.25 + 54.78 = 269.02 A
Starting Voltage Drop:
cosϕ = 0.3
sinϕ = 0.954
V_drop_start = [1.732 × I × (R × cosϕ + X × sinϕ) × L] / 1000
= [1.732 × 269.02 × (0.211 × 0.3 + 0.0718 × 0.954) × 550] / 1000
= [1.732 × 269.02 × (0.0633 + 0.0685) × 550] / 1000
= [1.732 × 269.02 × 0.1318 × 550] / 1000
= 33.78 V
% Voltage Drop = (33.78 / 415) × 100 = 8.14%
Conclusion: 8.14% < 10% → SAFE
Hence, Pure Tech suggests to the client / EPC to give a **single run of 3.5 Core, 185 [Link] Aluminium XLPE cable for the
OWS system main incomer cable.

Cable sizing calculation for dol startor motors:

Motor Power (P) = 1.5 kW = 1500 W
Voltage (V) = 415 V
Power Factor (cosϕ) = 0.8

Full Load Current = P / (√3 × V × cosϕ)

= 1500 / (1.732 × 415 × 0.8)
= 2.61 A
Cable Resistance (R) = 9.45 Ω/km
Reactance (X) = 0.099 Ω/km
Length (L) = 0.03 km/30 meter (considered max. Length)
Voltage Drop (V) = √3 × I × (R×cosϕ + X×sinϕ) × L
= 1.732 × 2.61 × (9.45×0.8 + 0.099×0.6) × 0.03
= 1.03 V
% Voltage Drop = (1.03 / 415) × 100
= 0.24 %
Cable current carrrying capacity = 34 A (× 0.8 derating) = 27.2 A

0.75 kW FLC = 750 / (1.732 × 415 × 0.8) = 1.30 A

0.375 kW FLC = 0.65 A
1.5 kW FLC = 2.60 A
Conclusion:
Recommended Cable : 3C x 2.5 sqmm Cu Armoured XLPE Cable is technically suitable for the given DOL starter motors.
Cable sizing calculation for 22kw motors:

Motor Power (P) = 22 kW = 22000 W

Voltage (V) = 415 V

Power Factor (cosϕ) = 0.8

Full Load Current = P / (√3 × V × cosϕ)

= 22000 / (1.732 × 415 × 0.8)

= 38.3 A

Cable Resistance (R) = 1.5 Ω/km

Reactance (X) = 0.08 Ω/km

Length (L) = 0.03 km/30meter (Considered [Link])

Voltage Drop (V) = √3 × I × (R×cosϕ + X×sinϕ) × L

= 1.732 × 38.3 × (1.5×0.8 + 0.08×0.6) × 0.03

= 1.52 V

% Voltage Drop = (1.52 / 415) × 100

= 0.36 %

Cable Capacity = 95 A (× 0.8 derating) = 75.2 A

Conclusion:
Recommended Cable : 3C x 25 sqmm Al. Armoured XLPE Cable is technically suitable for the given star-delta starter
motors.
 Cable Schedule

OWS POWER CABLE SCHEDULE:

Sl. Tag No Description FROM TO Cable details Gland Size

No
1 M-01 Floatin LCP MP-01 Motor Single RUN of 3 core * 2.5 [Link] 1/2’’
g Terminal Box Copper Armoured XLPE cable
Skimme
r
2 MP-02A Belt skimmer-1 LCP MP-02A Motor Single RUN of 3 core * 2.5 [Link] 1/2’’
Terminal Box Copper Armoured XLPE cable
3 MP-02B Belt skimmer-2 LCP MP-02B Motor Single RUN of 3 core * 2.5 [Link] 1/2’’
Terminal Box Copper Armoured XLPE cable
4 MP-03A Filter feed LCP M03A-Motor TWO RUN of 3 core * 25 [Link]
pump(working) Terminal Box AL. Armoured XLPE cable 1”

5 MP-03B Filter feed LCP M03B-Motor TWO RUN of 3 core * 25 [Link]

pump(standby) Terminal Box AL. Armoured XLPE cable 1”
6 MP-04A Oil transfer LCP M04A-Motor Single RUN of 3 core * 2.5 [Link] 1/2’’
pump(working) Terminal Box Copper Armoured XLPE cable

7 MP-04B Oil transfer LCP M04B-Motor Single RUN of 3 core * 2.5 [Link] 1/2’’
pump(standby) Terminal Box Copper Armoured XLPE cable
8 MP-05A Sludge LCP M05A-Motor Single RUN of 3 core * 2.5 [Link] 1/2’’
pump(working) Terminal Box Copper Armoured XLPE cable

9 MP-05B Sludge LCP M05B-Motor Single RUN of 3 core * 2.5 [Link] 1/2’’
pump(standby) Terminal Box Copper Armoured XLPE cable
10 MP-06A Treated water LCP M06A-Motor TWO RUN of 3 core * 25 [Link] 1”
transfer Terminal Box AL. Armoured XLPE cable
pump
(working)
11 MP-06B Treated LCP M06B-Motor TWO RUN of 3 core * 25 [Link] 1”
water Terminal Box AL. Armoured XLPE cable
transfer
pump
(standby)
12 - Power Cable LCP DOMS Panel Single RUN of 3 core * 2.5 [Link] 1/2’’
Copper Armoured XLPE cable
13 - MAIN CLIENT’ OWS LCP Single RUN of 3.5 core * 185 2”
INCOMING S MCC [Link] Copper Armoured XLPE
POWER CABLE* ROOM cable
 Cable Schedule

OWS CONTROL CABLE SCHEDULE:

Sl. Tag No. Description FROM TO Cable details Gland

No size

1 LS-1001 Level switch - 1 LCP LS1001 Terminal Box 4 core * 1.5 [Link] Copper 1/2”
Armoured XLPE cable

2 LS-1002 Level switch - 2 LCP LS1002 Terminal Box 4 core * 1.5 [Link] Copper 1/2”
Armoured XLPE cable

3 LS-1003 Level switch - 3 LCP LS1003 Terminal Box 4 core * 1.5 [Link] Copper 1/2”
Armoured XLPE cable

4 LS-1004 Level switch - 4 LCP LS1004 Terminal Box 4 core * 1.5 [Link] Copper 1/2”
Armoured XLPE cable

5 OS-01 Oil Float Switch-1 LCP OS-1 Terminal Box 4 core * 1.5 [Link] Copper 1/2”
Armoured XLPE cable

6 OS-2 Oil Float Switch-2 LCP OS-2 Terminal Box 4 core * 1.5 [Link] Copper 1/2”
Armoured XLPE cable

7 DPS-1 Differential Pressure LCP DPS-1 Terminal Box 4 core * 1.5 [Link] Copper 1/2”
switch - 1 Armoured XLPE cable

8 DPS-2 Differential Pressure DPS-1 DPS-2 Terminal Box 4 core * 1.5 [Link] Copper 1/2”
switch - 2 TB Armoured XLPE cable

9 SV-1 Solenoid Valve coil-1 LCP EPV-1 Solenoid 4 core * 1.5 [Link] Copper 1/2”
coil terminal box Armoured XLPE cable

10 SV-2 Solenoid Valve coil-2 LCP EPV-2 Solenoid 4 core * 1.5 [Link] Copper 1/2”
coil terminal box Armoured XLPE cable

11 DOMS DOMS / Purimeter LCP DOMS Panel 4 core * 1.5 [Link] Copper 1/2”
Armoured XLPE cable

12 CV-1 Control Valve -1 DOMS Control Valve - 1 4 core * 1.5 [Link] Copper 1/2”
Panel terminal box Armoured XLPE cable

13 CV-2 Electro-Pneumatic DOMS Control Valve - 2 4 core * 1.5 [Link] Copper 1/2”
Valve coil-4 Panel terminal box Armoured XLPE cable