APPENDIX C
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CLIENT:
PETRONAS CARIGALI SDN BHD [39275-U]
SARAWAK OPERATIONS
CT TITLE : FEASIBILITY STUDY FOR POWER UPGRADING AT
WLK-A
ENT TITLE : VOLTAGE DROP AND CABLE SIZING CALCULATION
ENT NO. : APPENDIX C
ORDER NO. : S04/J/184
REQUEST NO. : RNZ/09/0394
: 0001 DES
APPENDIX C
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TABLE OF CONTENTS
1.0 INTRODUCTION 3
2.0 OBJECTIVE 4
3.0 BASIS AND ASSUMPTION 5
3.1 Design Basis
5
3.2 Cable Sizing and Voltage Drop Calculation
5
3.3 Short Circuit Thermal Capacity
4.0 METHOD OF CALCULATION 7
4.1 New 500kW Gas Engine Genset
7
4.2 New 220kW Gas Engine Genset
5.0 CONCLUSION 11
APPENDICES
Appendix C-1 XLPE Insulated Power Cable Fujikura Catalogue
Appendix C-2 Merlin Gerin Technical Data Catalog
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APPENDIX C
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1.0 INTRODUCTION
PETRONAS CARIGALI SDN. BHD. Sarawak Operation (PCSB-SKO) currently intends
to upgrade the existing 220kW gas engine genset G-5640 with two options; 1) To
replace with a 500kW new gas engine genset and 2) To install additional 220kW gas
engine genset and run in parallel with the existing 220kW gas engine genset. This new
gas engine genset will also to cater for the existing largest motor loads for Option 1 and
load sharing scheme for Option 2.
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APPENDIX C
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2.0 OBJECTIVE
The objective of this document is to present the method and calculation in determining
the size of electrical cables percentage voltage drop for the new POWER
UPGRADING AT WLK-A PLATFORM.
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APPENDIX C
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3.0 BASIS AND ASSUMPTION
As per PTS [Link], for sizing of cables the following aspects shall be taken into
consideration:
- Continuous current carrying capacity
- Voltage drop
- Maximum cable loop impedance for earth faults in accordance with para. 3.8.3.
- Cable short circuit thermal capability
3.1 Design Basis
The estimated load is 500kW (Option 1) and 220kW (Option 2) based on output
kW rating of the new Genset.
The proposed size of the cable from genset to Switchgear SG-101 for Option 1
is 2nos. 4Cx300mm² XLPE/SWA/PVC and Option 2 is 1no. 4Cx240mm²
XLPE/SWA/PVC.
The estimate length of the cable from genset at new deck extension to
Switchgear SG-101 inside Switchgear Room is 23m for both options.
Cable impedances and current carrying capacity are based on “XLPE Insulated
Power Cables, Fujikura Federal Cables Sdn. Bhd” catalogue data.
Ambient air temperature is 40°C. All electrical cables are installed in air,
supported by cable ladders, trays and steelworks.
Group derating factor of current carrying capacity due to group installation of
cables on trays/ladders in air is assumed as 0.85.
Maximum allowable voltage drop shall not exceed 5% of nominal operational
voltage as per PTS [Link].
3.2 Cable Sizing and Voltage Drop Calculation
The permissible voltage drop at the load end during steady state is not more than 5%.
The voltage drop is given by the following formulae:
For Three Phase AC Power System,
3 x IFL x (Rcos + Xsin ) x L x 100%
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Vd =
Vn x 1000
Where,
Vn = Nominal voltage
Vd = Percentage of voltage drop
Vda = Permissible percentage of voltage drop
IFL = Full load current
cos = Power factor
R = Resistance (ohm / km)
X = Reactance (ohm / km)
L = Estimated cable length
Lmax = Maximum cable length
For the purpose of calculation the power factor of the distribution is assumed as 0.8
lagging during full load running.
3.3 Short Circuit Thermal Capacity
Based on “XLPE Insulated Power Cables, Fujikura Federal Cables Sdn. Bhd”
catalogue data, short circuit current carrying capacity is assessed from the following
formula. Cable is XLPE insulated, copper conductor cable.
I= 224 A ln( 234 1 / 234 0) = 142 A
t t
Where,
A = Cross sectional area of the conductor (mm2)
I = Short circuit current (A)
t = Total fault clearance time (seconds)
1 = Maximum permissible temperature at short circuit 250 0C
0 = Max. permissible continuous operating temp. 90 0C
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4.0 METHOD OF CALCULATION
4.1 New 500kW Gas Engine Genset
Voltage : 415V
Frequency : 50Hz
Full Load : 500kW (based on output kW rating of the genset)
Estimate Length : 23m
4.1.1 Continuous Current Carrying Capacity
Full Load Current (FLA) = Load (kW) x1000
3 x Voltage Rating x PF
= 500kW x 1000
3 x 415V x 0.8
= 869.503A
For Cable Size 2nos. 4Cx300mm2, current carrying capacity is 574A @ 40oC
Site Rating (A) = Current Carrying Capacity x Group Derating Factor x No
of conductor per phase
= 574 x 0.85 x 2
= 975.8A
The cable site rating shall be Full Load Current
869.503A
975.8A 869.503A (acceptable)
Thus, cable size shall be 2nos. 4Cx300mm2 XLPE/SWA/PVC.
4.1.2 Voltage Drop at Full Load
Vd = 3 x IFL x (Rcos + Xsin ) x L
3 x 1000
= 3 x 869.503 x (0.0799x0.8+0.0697x0.6) x 23
2 x 1000
= 1.831V
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Voltage Drop % = Vd x 100 %
Voltage Rating, Vn
= 1.831 x 100%
415
= 0.441%
Based on PTS [Link] voltage drop must be less than 5%. 0.441% is < 5%,
thus cable size is accepted.
4.1.3 Short Circuit Thermal Capacity
Bus fault MVA is based on genset load which is 500kW.
Bus fault MVA = base MVA = 500 = 0.625
0.8x1000
Zbus = 15% = 0.15pu
Short circuit level = Base MVA
Zbus
= 0.625
0.15
= 4.167kA
Short circuit current is taken as 4.167kA.
Cable Short Circuit Current Rating, I = 142 x A
t
Based on “Merlin Gerin Technical Data Catalog” the breaker fault clearance time, t=0.08s.
Selected cable size, A = 300mm²
Therefore;
Cable short circuit rating, I = 142 x A
t
= 142 x 300
0.08
= 150.614kA
150.614kA > Fault current of 4.167kA. Therefore, 2nos. 4Cx300mm2 cable size is
adequate.
4.2 New 220kW Gas Engine Genset
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Voltage : 415V
Frequency : 50Hz
Full Load : 220kW (based on output kW rating of the genset)
Estimate Length : 23m
4.2.1 Continuous Current Carrying Capacity
Full Load Current (FLA) = Load (kW) x1000
3 x Voltage Rating x PF
= 220kW x 1000
3 x 415V x 0.8
= 382.582A
For Cable Size 1no. 4Cx240mm2, current carrying capacity is 480A @ 40oC
Site Rating (A) = Current Carrying Capacity x Group Derating Factor x No
of conductor per phase
= 480 x 0.85 x 1
= 408A
The cable site rating shall be Full Load Current
382.582A
408A 382.582A (acceptable)
Thus, cable size shall be 1no. 4Cx240mm2 XLPE/SWA/PVC.
4.2.2 Voltage Drop at Full Load
Vd = 3 x IFL x (Rcos + Xsin ) x L
3 x 1000
= 3 x 382.582 x (0.0987x0.8+0.0703x0.6) x 23
2 x 1000
= 1.846V
Voltage Drop % = Vd x 100 %
Voltage Rating, Vn
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= 1.846 x 100%
415
= 0.445%
Based on PTS [Link] voltage drop must be less than 5%. 0.445% is < 5%,
thus cable size is accepted.
4.2.3 Short Circuit Thermal Capacity
Bus fault MVA is based on genset load which is 220kW.
Bus fault MVA = base MVA = 220 = 0.275
0.8x1000
Zbus = 15% = 0.15pu
Short circuit level = Base MVA
Zbus
= 0.275
0.15
= 1.833kA
Short circuit current is taken as 1.833kA.
Cable Short Circuit Current Rating, I = 142 x A
t
Based on “Merlin Gerin Technical Data Catalog” the breaker fault clearance time, t=0.08s.
Selected cable size, A = 240mm²
Therefore;
Cable short circuit rating, I = 142 x A
t
= 142 x 240
0.08
= 120.491kA
120.491kA > Fault current of 1.833kA. Therefore, 1nos. 4Cx240mm2 cable size is
adequate.
5.0 CONCLUSION
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APPENDIX C
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Based on the result of the calculations, the 2nos. 4Cx300mm2 cu. cable is acceptable
to be used for Option 1 and 1no. 4Cx240mm2 cu. cable is acceptable to be used for
Option 2.
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APPENDIX
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APPENDICES
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APPENDIX C-1
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APPENDIX C-1
XLPE INSULATED POWER CABLES FUJIKURA CATALOGUE
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APPENDIX C-2
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APPENDIX C-2
MERLIN GERIN TECHNICAL DATA CATALOGUE
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