Cable Sizing Fundamentals
&
Introduction to
Cable Sizing Tool
PDE Standardization 2013
Contents:
Need of optimal cable sizing.
Cable Construction
Standards for Sizing of Conductors
Cable Manufacturers in KSA
Criterion of Cable Sizing
Use of Cable Sizing Tool for optimal sizing of
Conductors as per IEC 60364.
Need for Optimal Cable Sizing:
-Hence
Oversized
Undersized cable
Optimalcables
lead
cable mayto result
sizingheavy
not in
cost
deformation
only of the project.
reduces of cable
the project
insulation
cost , excessive
but also ensure theheat
longlosses
life of &the
finally lead to short
cables.
circuit due to insulation damages.
Cable Construction
Construction Format :
[Link]
Conductor
/ Insulation
(e.g. Cu//Armor
Al) / Outer Sheath
2. Examples:
Insulation (PVC / XLPE)
• Cu / XLPE / SWA / PVC
3. • Armour
CU / PVC(SWA / STA
/ SWA /Unarmored)
/ PVC
• CU / XLPE / Unarmored / PVC
4. • Outer Sheath (PVC)
CU / PVC / Unarmored / PVC
Cable Construction
Standard format for writing cable specifications
Consider a cable with specifications as under:
1 – 4/C x 50mm2 , CU/XLPE/SWA/PVC, 0.6/1kV
No. of Sets
No. ofofCores
Cables
Cross-section
per(Conductors
cableCable
AreaConstruction
ofper
Conductor
phase) in eachVoltage
core Grade
Standards for Cable Sizing:
NEC
Article 310
SEC SBC
Chapter 52
TES-P-104-03-R0
IEC International
Local IEEE
Std. 399
60364-5-52 Standards
Standards
BS
MAADEN
7671
MD-405-10P0-EG-
EL-SPC-00003
Cable Manufactures in KSA
Saudi Jeddah
Cables Cables
Cable
Manufacturer
Riyadh
Cables
Cable sizing Criterion:
There are THREE main checks for sizing of conductors:
Ampacity
Voltage
Drop
SC
Withstand
capability
Ampacity Check:
Ampacity
(Current carrying
capacity)
Ampacity
Ampacity:
Ampacity refers to current carrying capacity of the
conductors under standard conditions.
Cables having same cross-sectional areas may not
necessarily have the same Ampacity, as Ampacity also
depends upon:
• Conductor type (i.e. Cu / Al) ,
• Insulation type (XLPE/ PVC) ,
• Armour Type (SWA / Unarmored)
• Method of Installation
- Above ground in Cable trays
- Below ground in trenches
Ampacity
Ampacity:
Example:
Suppose we have 4 cables with CSA=50mm2
Cable Spec Install. Method Ampacity
1-3/C x 50mm2 Cu/XLPE/SWA/PVC Installed in Air 182 Amps
1-3/C x 50mm2 Cu/XLPE/SWA/PVC Installed in Gnd 189 Amps
1-3/C x 50mm2 Cu/PVC/SWA/PVC Installed in Air 128 Amps
1-3/C x 50mm2 Cu/XLPE/UnArm/PVC Installed in Air 175 Amps
Ampacity
Ampacity Condition:
For a conductor to satisfy Ampacity criteria , the following
condition must meet after selecting a cable:
Ib < Ir < Iz
Iz:: Continuous
IIr:
b Corrected Permissible
Current Setting Conductor
LoadofCurrent.
Protective Current
device
(Derated Ampacity based on Site conditions & installation method)
Ib < Ir < Iz
Ampacity
Ampacity:
Iz (I Derated) = K x Iz’(I Base)
Iz’: Permissible Conductor Current
(from Manufacturers cable catalogue- Base Ampacity)
Where K= K1 x K2 x K3 x K4
K1= Correction factor for Temperature
K2= Correction Factor for Group of cables
K3= Correction factor for Soil thermal resistivity
K4= Correction factor for depth of burial
Ampacity
Ampacity:
Correction Factors (K):
K1=
K3= Correction factor
K2= Factorfor forTemperature
Group
Soil of cables
Thermal Resistivity
K2= Correction
(IEC-60364-5-52 ,Table Factor
A.52-14 & for
A.52-17
A.52-16) 15) Group of cables
18)
K3= Correction factor for Soil thermalExample: resistivity
K4= Depth of Burial Factor For 50mm2 cable,
K4= Correction
(IEC-60364-5-52 ,Table factor
A.52-16) for depth of burial
@
@p=302.5
n=1
o
C,K2=1,
,K1=1,
K. m/W
Ampacity=175A
Ampacity=175A
K3= 1
Ampacity Condition (Summary): @ Ampacity=175A
50oC,K1=0.82,
n=4 ,K2=0.77, Ampacity=
@ p= 3 K. m/W
Ampacity= 111A
144A
Ib < Ir < Iz K3= 0.96
Ampacity=168A
Where Iz (IDerated) = K x Iz’ (IBase)
K= K1 x K2 x K3 x K4
Voltage Drop Check:
Voltage Drop
Voltage
Drop
Voltage Drop:
“Every electrical load is characterized by Rated Voltage
that must be within the tolerance as specified by the
manufacturer.”
If the loads are at farther location from the power supply
source, Voltage drop may become a serious issue!!!!
So, the voltage drop should be in tolerable limit,
as specified in the customer’s specs.
Voltage
Drop
Voltage Drop Formulae: IEC
NEC
IEEE
1-Phase:
Vd = 2 x I x L x ([Link]ø + [Link]ø)
3-Phase:
Vd = Sqrt(3) x I x L x ([Link]ø + [Link]ø)
Where,
Vd = Voltage Drop (Volts) From
I = load Current (Amps) ~ Ib Manufacturer’s
L = Length of Cable (km) Catalogue
R = Resistance (Ohms / km)
X = Reactance (Ohms / km)
Cosø = Load Power Factor
Sinø = Sin (Cos-1 ø)
Voltage
Drop
Voltage Drop Formulae: BS
7671
1-Phase:
Vd = I x L x mV/A/m
3-Phase:
Vd = Sqrt(3) x I x L x mV/A/m
Where,
Vd = Voltage Drop (Volts) From
Manufacturer’s
I = load Current (Amps) ~ Ib Catalogue
L = Length of Cable (km)
mV/A/m = Cable Voltage Drop factor
Voltage
Drop
% Voltage Drop:
Usually Voltage Drop is expressed in percentage
of source voltage.
Vd % = (Vd x 100)/Vs
Where, Vd = Voltage Drop (Volts)
Vs = Power Supply Source Voltage
Voltage Drop Calculations for Motors:
For motor loads, we need to check:
1) Steady State Voltage Drop
(Calculations will same as that of non-motor loads)
2) Starting Voltage Drop
Vd = Sqrt(3) x Istarting x L x ([Link]øs + [Link]øs)
Where,
Vd = Voltage Drop (Volts)
Istarting = Motor Starting Current (Amps) ~ 4 – 6 x IFL
L = Length of Cable (km)
R = Resistance (Ohms / km)
X = Reactance (Ohms / km)
Cosøs = Starting Power Factor
Sinøs = Sin (Cos-1 øs)
Allowable Voltage Drop for Motors:
Allowable Voltage Drop during motor starting depends on the Torque speed
characteristic curve.
For example for NEMA Design B motors , the starting voltage drop should
not be less than 20%.
As per IEC, if the steady state voltage is more than 8% , then It would not let
the motor to accelerate because of high voltage drop during starting (i.e.
approximately 40%).
Cable SC Withstand Capability:
Cable SC
Withstand
Capability
SC
Cable SC Withstand Capability: Withstand
capability
For a given cable size “S” (in mm2), the cable
Short Circuit Withstand capability for a particular
duration of time is calculated by this equation
Where ,
“K” is Temperature Coefficient of Conductor Resistance
“t” is the duration of fault current (typically taken as 1 sec)
SC
Cable SC Withstand Capability: Withstand
capability
For a cable to satisfy Criteria of SC Withstand capability.
The cable SC Withstand Capability shall be greater then
the available fault current (3-Ph Sym. SC current).
Example#1: Can a cable with specifications 1-3/C x
50mm2 ,CU/ XLPE/SWA/PVC is used as outgoing feeder from a
unit substation with Available fault current of 21kA rms ?
Solution: By putting values in the given equation,
S=50
K= 143 (for Cu/XLPE type cables)
t = 1 sec
I= 7.15kA < 21kA
Hence cable is not suitable with regards to SC Capability of
cable.
SC
Cable SC Withstand Capability: Withstand
capability
Example#2:
Can a cable with specifications 1-3/C x 150mm2 ,CU/ XLPE/SWA/PVC is used as
outgoing feeder from a unit substation with Available fault current of 21kA rms ?
Solution:
By putting values in the given equation,
S=150
K= 143 (for Cu/XLPE type cables)
t = 1 sec
I= 21.45kA > 21kA
Hence cable is suitable with regards to SC Capability of cable.
Cable sizing Criterion:
There are THREE main checks for sizing of conductors:
Ampacity
Voltage
Drop
SC
Withstand
capability
Introduction to Cable Sizing Tool
ANY QUESTIONS
