BGR ENERGY SYSTEMS LTD.

POWER PROJECTS DIVISION SHEET 1 OF 7

LT CABLE SIZING CALCULATIONS Rev A

TRN THERMAL POWER PROJECT

2 X 300 MW

BGR ENERGY SYSTEMS LIMITED

POWER PROJECTS DIVISION

PLOT NO.1, SECTOR 16A,

FILM CITY, NOIDA

PH 0120 4532300

E Mail – [email protected]

10.02.2012 VV MS SD

DATE PREPARED BY CHECKED BY APPROVED BY

 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 2 OF 7

LT CABLE SIZING CALCULATIONS Rev A

CALCULATION METHOD & SAMPLE CALCULATION FOR LT CABLES

1.0 OBJECTIVE

The scope of this document covers cable sizing and voltage drop calculation for incomer & outgoing
feeders and Motor feeders of LT switchboards, to be adopted for 2x300 MW coal based Thermal power
plant at NAWAPARA, CHHATTISGARH State. This document also defines the technical basis,
parameters and criteria used for calculations of required no. of runs and sizes of cables to be selected.

2.0 SITE CONDITIONS

a. Ambient Temperature : 50˚C/6.2˚c (Max/Min)

b. Ground Temperature : 40˚C
c. Laying Of Cables : Overhead Cable trays, Cables laid in cable trench
d. Depth of laying : 1000 mm (Min.) for buried cables laid in Hume/
Galvanized iron pipe.

3.0 CABLE INSTALLATION

The following methods for cable installations are considered:

a. Tray in the open air

b. Buried cables through Hume/Galvanized iron pipe
c. Cable trays on concrete cable trench with precast covers

4.0 GENERAL

4.1 The cable sizing is based on the following criteria :-

a. Full load current carrying capacity under installation conditions (i.e. with suitable derating
factors to cover site conditions such as ambient temperature, grouping and cables laying
configurations).
b. Voltage drop calculation during starting and running condition of motors.

4.2 Temperature Condition of calculation shall be as follows:-

a. Max. Conductor Temp. (Continuous) : 90˚C ( For XLPE Cables )

b. Max. Conductor Temp. (Short Circuit) : 250˚C ( For XLPE Cables )
c. Conductor Material : Aluminium ( for area ≥16 sq. mm)
: Copper (for area < 16 sq. mm)

5.0 DOCUMENT REFERENCE

a. POLYCAB CATALOG for Low Tension Motors

b. ABB MOTORS

6.0 DESIGN CONSIDERATIONS

 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 3 OF 7

LT CABLE SIZING CALCULATIONS Rev A

6.1 MAX. PERMISSIBLE VOLTAGE DROP

a. Incomer Feeder/Outgoing Feeder : 2.5%

b. Motor Running at full load : 2.5%
c. Motor Starting : 10%

6.2 FAULT CLEARING TIME

a. 415 V Switchgear : 1 sec

b. 415V Motor feeder with : 0.25 sec
Instantaneous O/C Protection
c. 415V Outgoing feeder with : 0.25 sec
Instantaneous O/C Protection

6.3 CABLE MANUFACTURER DATA: (REF – POLYCAB, LOW TENSION XLPE CABLES )

TEMPERATURE FACTOR GROUPING DERATING

METHOD OF LAYING TYPE (AMBIENT FACTOR) FACTOR FACTOR
For 50 ͦC (TF) (GF) (DF)

Laid in cable tray Multicore

cables- 9 cables per tray & 3 A 0.68 0.612
trays in tier – Cables touching
formation
Laid in cable tray Multicore
cables – 6 cables per tray & 3 B 0.89 0.801
trays in tier -1 dia. Spacing
0.9

Laid in cable tray Single core

Cables- 3 Trefoils per tray & 3 C 0.92 0.828
trays in tier - 2 dia. spacing

7.0 METHOD OF CALCULATION

7.1 CABLE SIZES BASED ON LOAD CURRENT CARRYING CAPACITY

Full load current carrying capacity of cable will be corrected by derating factor and shall be larger
than the load current.

Iamp = Ibase x DF ˃ IFLC

IFLC = Rated Power / [(√3) x V x PF x Efficiency]

DF = G F x T F
 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 4 OF 7

LT CABLE SIZING CALCULATIONS Rev A

Where:
Iamp = Corrected Cable Current (Amp)
Ibase = Base Cable Current Carrying Capacity (Amp)
IFLC = Full Load Current (Amp)
DF = Derating Factor
GF = Group Derating Factor
TF = Ambient Temperature Factor

7.2 VOLTAGE DROP CALCULATION

The voltage drop calculation shall be carried out as follows:

%VDR = (((√3) x ILR x L x (R cosᶲR + X sinᶲR)) x 100)/ (1000 x V x n)

%VDS = (((√3) x ILS x L x (R cosᶲS + X sinᶲS)) x 100)/ (1000 x V x n)

Where:
%VDR = % Voltage drop in running condition
%VDS = % Voltage drop in starting condition
ILR = Full load current in running condition
ILS = Full load current in starting condition (6 x ILR)
L = Length of the cable route (mtr)
R = Resistance of the cable (Ω/km)
X = Reactance of the cable (Ω/km)
cosᶲR = Power Factor in running condition
cosᶲS = Power Factor in starting condition
sinᶲR = Sine value of angle corresponding to power factor in running condition
sinᶲS = Sine value of angle corresponding to power factor in starting condition
V = Rated Voltage (v)
N = No. of runs of cable running in parallel per phase

8.0 SAMPLE CALCULATION

8.1 For 30 kW motor

Length of the cable : 100 Meters (Approx.)

Motor Rating : 30 kW
Voltage Level : 415 V
Power Factor : 0.830 [ABB Cat.]
Efficiency : 0.926 [ABB cat.]

A. CABLE SIZES BASED ON LOAD CURRENT CARRYING CAPACITY

Full load current carrying capacity of cable will be calculated as per clause no. 7.1

IFLC = (30 x 1000) / [(√3)*415*0.83*0.926] = 54.305 A

Ibase = 117 A [since 3C x 35 Sq. mm cable is considered from Polycab Cat.]

 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 5 OF 7

LT CABLE SIZING CALCULATIONS Rev A

GF = 0.68 (Laid in cable tray Multicore cables- 9 cables per tray & 3 trays in tier – Cables
touching formation)

TF = 0.9 (For ambient temperature)

DF = 0.9 x 0.68 = 0.612

Full load current carrying capacity of cable will be corrected by derating factor and shall be
larger than the load current

Iamp = Ibase * DF ˃ IFLC

Iamp = Ibase x DF = 117 x 0.612 = 71.604 Amp

Since 71.604 Amp ˃ 54.305 Amp

Hence Satisfied

Therefore number of runs of cable:

n = IFLC/ Iamp = 54.305/71.604 = 0.758

Hence, No. of runs per phase = 1

B. VOLTAGE DROP CALCULATION

The voltage drop will be calculated as per clause no. 7.2

%VDR = (((√3) x ILR x L x (R cosᶲR + X sinᶲR)) x 100) / (1000 x V x n)

%VDS = (((√3) x ILS x L x (R cosᶲS + X sinᶲS)) x 100) / (1000 x V x n)

ILR = IFLC = 54.305 Amp

ILS = 6 x ILR = 6 x 54.305 =325.827 Amp

L = 100 mts

R = 1.110 (Ω/km) [Polycab Cat.]

X = 0.0783 (Ω/km) [Polycab Cat.]

cosᶲR = 0.83 [ABB Cat.]

cosᶲS = 0.2

sinᶲR = 0.558

sinᶲS = 0.98

V = 415 (v)
 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 6 OF 7

LT CABLE SIZING CALCULATIONS Rev A

n =1

%VDR =2.187 % ˂ 2.5%

%VDS = 4.062 % ˂ 10%

S. NO. DESCRIPTION RESULT CONCLUSION REMARKS

1 Is Iamp˃(IFLC/n) YES HENCE SAFE

2 Is %VDR is under permissible YES HENCE SAFE

drop
3 Is %VDS is under permissible YES HENCE SAFE
drop
HENCE THE SELECTED CABLE SIZE of 3CX35 SQ MM (1 Run), AL. Arm. XLPE CABLE IS
ADEQUATE.

9.0 SAMPLE CALCULATION

9.1 For 110 kW motor

Length of the cable : 100 Meters (Approx.)

Motor Rating : 110 kW
Voltage Level : 415 V
Power Factor : 0.860 [ABB Cat.]
Efficiency : 0.952 [ABB cat.]

B. CABLE SIZES BASED ON LOAD CURRENT CARRYING CAPACITY

Full load current carrying capacity of cable will be calculated as per clause no. 7.1

IFLC = (110 x 1000) / [(√3)*415*0.860*0.952] = 186.922 A

Ibase = 337 A [since 3C x 240 Sq. mm cable is considered from Polycab Cat.]

GF = 0.68 (Laid in cable tray Multicore cables- 9 cables per tray & 3 trays in tier – Cables
touching formation)

TF = 0.9 (For ambient temperature)

DF = 0.9 x 0.68 = 0.612

Full load current carrying capacity of cable will be corrected by derating factor and shall be
larger than the load current
 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 7 OF 7

LT CABLE SIZING CALCULATIONS Rev A

Iamp = Ibase * DF ˃ IFLC

Iamp = Ibase x DF = 337 x 0.612 = 206.244 Amp

Since 206.244 Amp ˃ 186.922 Amp

Hence Satisfied

Therefore number of runs of cable:

n = IFLC/ Iamp = 186.922/206.244 = 0.906

Hence, No. of runs per phase = 1

B. VOLTAGE DROP CALCULATION

The voltage drop will be calculated as per clause no. 7.2

%VDR = (((√3) x ILR x L x (R cosᶲR + X sinᶲR)) x 100) / (1000 x V x n)

%VDS = (((√3) x ILS x L x (R cosᶲS + X sinᶲS)) x 100) / (1000 x V x n)

ILR = IFLC = 186.922 Amp

ILS = 6 x ILR = 6 x 54.305 =1121.534 Amp

L = 100 mts

R = 0.210 (Ω/km) [Polycab Cat.]

X = 0.0718 (Ω/km) [Polycab Cat.]

cosᶲR = 0.860 [ABB Cat.]

cosᶲS = 0.2

sinᶲR = 0.510

sinᶲS = 0.980

V = 415 (v)

n =1

%VDR =1.695 % ˂ 2.5%

%VDS = 5.259 % ˂ 10%

S. NO. DESCRIPTION RESULT CONCLUSION REMARKS

 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 8 OF 7

LT CABLE SIZING CALCULATIONS Rev A

1 Is Iamp˃(IFLC/n) YES HENCE SAFE

2 Is %VDR is under permissible YES HENCE SAFE

drop
3 Is %VDS is under permissible YES HENCE SAFE
drop
HENCE THE SELECTED CABLE SIZE of 3CX185 SQ MM (1 Run), AL. Arm. XLPE CABLE IS
ADEQUATE.

10.0 SAMPLE CALCULATION

10.1 For 150 kW motor

Length of the cable : 100 Meters (Approx.)

Motor Rating : 150 kW
Voltage Level : 415 V
Power Factor : 0.870 [ABB Cat.]
Efficiency : 0.958 [ABB cat.]

C. CABLE SIZES BASED ON LOAD CURRENT CARRYING CAPACITY

Full load current carrying capacity of cable will be calculated as per clause no. 7.1

IFLC = (150 x 1000) / [(√3)*415*0.870*0.958] = 250.386 A

Ibase = 455 A [since 3C x 300 Sq. mm cable is considered from Polycab Cat.]

GF = 0.68 (Laid in cable tray Multicore cables- 9 cables per tray & 3 trays in tier – Cables
touching formation)

TF = 0.9 (For ambient temperature)

DF = 0.9 x 0.68 = 0.612

Full load current carrying capacity of cable will be corrected by derating factor and shall be
larger than the load current

Iamp = Ibase * DF ˃ IFLC

Iamp = Ibase x DF = 455 x 0.612 = 278.460 Amp

Since 278.460 Amp ˃ 250.386 Amp

Hence Satisfied

Therefore number of runs of cable:

 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 9 OF 7

LT CABLE SIZING CALCULATIONS Rev A

n = IFLC/ Iamp = 250.386/278.460 = 0.899

Hence, No. of runs per phase = 1

B. VOLTAGE DROP CALCULATION

The voltage drop will be calculated as per clause no. 7.2

%VDR = (((√3) x ILR x L x (R cosᶲR + X sinᶲR)) x 100) / (1000 x V x n)

%VDS = (((√3) x ILS x L x (R cosᶲS + X sinᶲS)) x 100) / (1000 x V x n)

ILR = IFLC = 250.385 Amp

ILS = 6 x ILR = 6 x 250.385 =1502.318 Amp

L = 100 mts

R = 0.128 (Ω/km) [Polycab Cat.]

X = 0.0705 (Ω/km) [Polycab Cat.]

cosᶲR = 0.870 [ABB Cat.]

cosᶲS = 0.2

sinᶲR = 0.493

sinᶲS = 0.980

V = 415 (v)

n =1

%VDR =1.527 % ˂ 2.5%

%VDS = 5.936 % ˂ 10%

 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 10 OF 7

LT CABLE SIZING CALCULATIONS Rev A

S. NO. DESCRIPTION RESULT CONCLUSION REMARKS

1 Is Iamp˃(IFLC/n) YES HENCE SAFE

2 Is %VDR is under permissible YES HENCE SAFE

drop
3 Is %VDS is under permissible YES HENCE SAFE
drop
HENCE THE SELECTED CABLE SIZE of 3CX300 SQ MM (1 Run), AL. Arm. XLPE CABLE IS
ADEQUATE.

11.0 SAMPLE CALCULATION

11.1 For 160 kW motor

Length of the cable : 100 Meters (Approx.)

Motor Rating : 160 kW
Voltage Level : 415 V
Power Factor : 0.870 [ABB Cat.]
Efficiency : 0.958 [ABB cat.]

D. CABLE SIZES BASED ON LOAD CURRENT CARRYING CAPACITY

Full load current carrying capacity of cable will be calculated as per clause no. 7.1

IFLC = (160 x 1000) / [(√3)*415*0.870*0.958] = 267.079 A

Ibase = 455 A [since 3C x 300 Sq. mm cable is considered from Polycab Cat.]

GF = 0.68 (Laid in cable tray Multicore cables- 9 cables per tray & 3 trays in tier – Cables
touching formation)

TF = 0.9 (For ambient temperature)

DF = 0.9 x 0.68 = 0.612

Full load current carrying capacity of cable will be corrected by derating factor and shall be
larger than the load current

Iamp = Ibase * DF ˃ IFLC

Iamp = Ibase x DF = 455 x 0.612 = 278.460 Amp

Since 278.460 Amp ˃ 267.079 Amp

Hence Satisfied

Therefore number of runs of cable:

 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 11 OF 7

LT CABLE SIZING CALCULATIONS Rev A

n = IFLC/ Iamp = 267.079/278.460 = 0.959

Hence, No. of runs per phase = 1

B. VOLTAGE DROP CALCULATION

The voltage drop will be calculated as per clause no. 7.2

%VDR = (((√3) x ILR x L x (R cosᶲR + X sinᶲR)) x 100) / (1000 x V x n)

%VDS = (((√3) x ILS x L x (R cosᶲS + X sinᶲS)) x 100) / (1000 x V x n)

ILR = IFLC = 267.079 Amp

ILS = 6 x ILR = 6 x 267.069 =1602.472 Amp

L = 100 mts

R = 0.128 (Ω/km) [Polycab Cat.]

X = 0.0705 (Ω/km) [Polycab Cat.]

cosᶲR = 0.870 [ABB Cat.]

cosᶲS = 0.2

sinᶲR = 0.493

sinᶲS = 0.980

V = 415 (v)

n =1

%VDR =1.526 % ˂ 2.5%

%VDS = 6.695 % ˂ 10%

 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 12 OF 7

LT CABLE SIZING CALCULATIONS Rev A

S. NO. DESCRIPTION RESULT CONCLUSION REMARKS

1 Is Iamp˃(IFLC/n) YES HENCE SAFE

2 Is %VDR is under permissible YES HENCE SAFE

drop
3 Is %VDS is under permissible YES HENCE SAFE
drop
HENCE THE SELECTED CABLE SIZE of 3CX300 SQ MM (1 Run), AL. Arm. XLPE CABLE IS
ADEQUATE.

12.0 SAMPLE CALCULATION

12.1 For 200 kW motor

Length of the cable : 100 Meters (Approx.)

Motor Rating : 160 kW
Voltage Level : 415 V
Power Factor : 0.880 [ABB Cat.]
Efficiency : 0.968 [ABB cat.]

E. CABLE SIZES BASED ON LOAD CURRENT CARRYING CAPACITY

Full load current carrying capacity of cable will be calculated as per clause no. 7.1

IFLC = (200 x 1000) / [(√3)*415*0.870*0.958] = 329.357 A

Ibase = 612 A [since 3C x 500 Sq. mm cable is considered from Polycab Cat.]

GF = 0.68 (Laid in cable tray Multicore cables- 9 cables per tray & 3 trays in tier – Cables
touching formation)

TF = 0.9 (For ambient temperature)

DF = 0.9 x 0.68 = 0.612

Full load current carrying capacity of cable will be corrected by derating factor and shall be
larger than the load current

Iamp = Ibase * DF ˃ IFLC

Iamp = Ibase x DF = 612 x 0.612 = 374.544 Amp

Since 374.544 Amp ˃ 329.357 Amp

Hence Satisfied
 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 13 OF 7

LT CABLE SIZING CALCULATIONS Rev A

Therefore number of runs of cable:

n = IFLC/ Iamp = 329.357/374.544 = 0.879

Hence, No. of runs per phase = 1

B. VOLTAGE DROP CALCULATION

The voltage drop will be calculated as per clause no. 7.2

%VDR = (((√3) x ILR x L x (R cosᶲR + X sinᶲR)) x 100) / (1000 x V x n)

%VDS = (((√3) x ILS x L x (R cosᶲS + X sinᶲS)) x 100) / (1000 x V x n)

ILR = IFLC = 329.3573 Amp

ILS = 6 x ILR = 6 x 267.069 =1976.142 Amp

L = 100 mts

R = 0.0714 (Ω/km) [Polycab Cat.]

X = 0.0702 (Ω/km) [Polycab Cat.]

cosᶲR = 0.88 [ABB Cat.]

cosᶲS = 0.2

sinᶲR = 0.475

sinᶲS = 0.980

V = 415 (v)

n =1

%VDR =1.32 % ˂ 2.5%

%VDS = 6.851 % ˂ 10%

 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 14 OF 7

LT CABLE SIZING CALCULATIONS Rev A

S. NO. DESCRIPTION RESULT CONCLUSION REMARKS

1 Is Iamp˃(IFLC/n) YES HENCE SAFE

2 Is %VDR is under permissible YES HENCE SAFE

drop
3 Is %VDS is under permissible YES HENCE SAFE
drop
HENCE THE SELECTED CABLE SIZE of 3CX500 SQ MM (1 Run), AL. Arm. XLPE CABLE IS
ADEQUATE.
 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 15 OF 7

LT CABLE SIZING CALCULATIONS Rev A

 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 16 OF 7

LT CABLE SIZING CALCULATIONS Rev A

Derating Factors
for Cable
Cable Size
Selected
Rating in kW for Motors / kVA

No. of runs required rounded

No. of runs required to carry

Voltage drop during starting

Power Factor CosΦ (Starting
(Steady state Condition)
Current Rating of Cable in
(Running condition)

Full Load Current (IL)

for Transformers

(Starting Condition)
Resistance of Cable (R)
Length of the Cable (L)
Derated current carrying

Steady State voltage drop

Reactance of Cable (XL)
Full Load current
Starting Current
Power Factor CosΦ

(Ohm/Km)

(Ohm/Km)

condition)
Efficency

(mts)

(%)

Remarks
Air (A)
Voltage (V)

capacity

(%)
off
(A)

SinΦ

SinΦ
Grouping
Ambient
Size

Total

22.000 415.000 0.830 0.915 40.302 241.813 3C x 25 96.000 0.900 0.680 0.612 58.752 0.686 1.000 100.000 1.540 0.081 0.558 2.225 0.200 0.980 3.904 SAFE

30.000 415.000 0.830 0.926 54.305 325.827 3C x 35 117.000 0.900 0.680 0.612 71.604 0.758 1.000 100.000 1.110 0.078 0.558 2.187 0.200 0.980 4.062 SAFE

37.000 415.000 0.830 0.928 66.831 400.988 3C X 35 117.000 0.900 0.680 0.612 71.604 0.933 1.000 90.000 1.110 0.078 0.558 2.422 0.200 0.980 4.499 SAFE

45.00 415.000 0.830 0.933 80.846 485.074 3C x 50 142.000 0.900 0.680 0.612 86.904 0.930 1.000 100.000 0.820 0.075 0.558 2.438 0.200 0.980 4.808 SAFE

55.000 415.000 0.830 0.938 98.285 589.708 3C X 70 179.000 0.900 0.680 0.612 109.548 0.897 1.000 100.000 0.567 0.074 0.558 2.100 0.200 0.980 4.575 SAFE

75.000 415.000 0.850 0.938 130.871 785.226 3C X 95 221.000 0.900 0.680 0.612 135.252 0.968 1.000 100.000 0.410 0.072 0.527 2.112 0.200 0.980 5.012 SAFE

90.000 415.000 0.850 0.940 156.711 940.267 3C X 120 257.000 0.900 0.680 0.612 157.284 0.996 1.000 100.000 0.324 0.071 0.527 2.047 0.200 0.980 5.280 SAFE

110.000 415.000 0.860 0.952 186.922 1121.534 3C x 185 337.000 0.900 0.680 0.612 206.244 0.906 1.000 100.000 0.210 0.072 0.510 1.695 0.200 0.980 5.259 SAFE

125.000 415.000 0.870 0.954 209.530 1257.181 3C x 240 399.000 0.900 0.680 0.612 244.188 0.858 1.000 100.000 0.160 0.071 0.493 1.523 0.200 0.980 5.329 SAFE

132.000 415.000 0.870 0.955 221.032 1326.193 3C x 240 399.000 0.900 0.680 0.612 244.188 0.905 1.000 100.000 0.160 0.071 0.493 1.607 0.200 0.980 5.622 SAFE

150.000 415.000 0.870 0.958 250.386 1502.318 3C x 300 455.000 0.900 0.680 0.612 278.460 0.899 1.000 100.000 0.128 0.071 0.493 1.527 0.200 0.980 5.936 SAFE

160.000 415.000 0.870 0.958 267.079 1602.472 3C x 300 455.000 0.900 0.680 0.612 278.460 0.959 1.000 100.000 0.128 0.071 0.493 1.629 0.200 0.980 6.332 SAFE

180.000 415.000 0.870 0.958 300.464 1802.781 3C x 400 530.000 0.900 0.680 0.612 324.360 0.926 1.000 100.000 0.070 0.100 0.493 1.386 0.200 0.980 8.431 SAFE

200.000 415.000 0.880 0.960 329.367 1976.202 3C x 500 612.000 0.900 0.680 0.612 374.544 0.879 1.000 100.000 0.071 0.070 0.475 1.322 0.200 0.980 6.851 SAFE
 BGR ENERGY SYSTEMS LTD.
POWER PROJECTS DIVISION SHEET 17 OF 7

LT CABLE SIZING CALCULATIONS Rev A