cCALCULATION 8074-13-CA-05

CABLE SIZING CALCULATION

SHEETS SHEET 1 OF 4

1.0 SCOPE

1.1 The scope of this calculation is to determine the sizes of new power cables applicable for the Urea
Expansion Project.

2.0 METHODOLOGY

2.1 The power cable feeding to each load is sized based on following criteria.

i) Voltage drop while carrying rated load current

ii) Voltage drop at motor starting condition.
iii) Derated continuos current carrying capacity of the cable.
iv) Short time current rating of the cable

2.2 Voltage Drops

a) The voltage drop in a three phase circuit cable is computed using following formula.

Formula-1

% Volatge Drop = 3*I (r cosø + x sinø )*L*100

V
Where I = Line current in Amps
r = Resistance/conductor/m
x = Reactance/conductor/m
cosø = Power factor
L = Cable length in m
V = Line to line voltage in V
b) The voltage drop during motor staring condition is computed by using staring current and starting
power factor as applicable in the above formula.

c) The voltage drop for a single phase circuit cable is given by Formula-2 given below.

Formula-2

% Volatge Drop = 2*I (r cosø + x sinø )*L*100

V
Where I = Line current in Amps
r = Resistance/conductor/m
x = Reactance/conductor/m
cosø = Power factor
L = Cable length in m
V = Line to line voltage in V

d) The allowable voltage drops are given in Table-1. The cable sizes are selected to achieve voltage
drops lesser than or equal to the allowable values , for the load current applicable.
0 17-11-99 TSM -
REV DATE PRPD CHKD APPRD REV DATE PRPD CHKD APPRD
FACT ENGINEERING AND DESIGN ORGANISATION
CUSTOMER : NFL UCSA Ref. No.8073-ECC-001 Rev/
PLANT LOCATION : NANGAL INDIA JOB No: 8073 Sheet 1 of 4
PROJECT : NANGAL UREA EXPANSION CAPACITY INCREASE BY 450 MTPD
 8074-13-CA-05
CALCULATION CABLE SIZING CALCULATION
SHEETS SHEET 2 OF 4

2.3 Derating factors

a) The cable currents furnished by the manufacturer is for 40 0C ambient temperature. Since the
specified ambient temperature at site is 50 0C, the cable current is to be derated by 0.8 as per derating
tables published.

b) The cables are to be laid in overhead trays with cables touching. The cables are operated at currents
lower than the rated values and cables in each tray route include control cables carrying low currents
and spare feeder cables carrying no currents. The derating factor adopted as per standard practice
considering the above is 0.75.

c) The overall derating factor = 0.8*0.75 = 0.6. The cable sizes are selected to achieve derating factor
lesser than or equal to 0.6, for the load current applicable.

2.4 Short time rating

a) The 11kV circuit breakers, 3.3kV breakers and 415V ACBs take 1.5 to 4 cycles to clear the faults.
Hence cables controlled by these devices are to be sized to withstand the fault currents let through by
these devices. For MCCB controlled feeders the fault current is reduced due to the current limiting
property of the MCCB and MCCB clears the fault current within the first cycle. The fault current and
minimum withstand time required for different cables are given in Table – 1 below. For fault current
computation refer our Doc. No. 8074-13-CA-01.

TABLE -1: Cable Sizing Criteria

No Cables % Voltage % Voltage Derating Short time current ratings
Drop (Run) Drop (Start) factor Fault kA Withstand
time (sec)
1 11kV Feeder 2.5 NA 0.6 13.1 0.2
Cable
2 11kV Motor 2.5 15 0.6 13.1 0.2
Cable
3 3.3kV Feeder 2.5 NA 0.6 13.6 0.2
Cable
4 3.3kV Motor 2.5 15 0.6 13.6 0.2
Cable
5 415V cables 2.5 NA 0.6 28.8 0.2
for ACB
feeders
6 415 cables for 2.5 15 0.6 28.8 0.2
ACB fed
motors
7 415 cables for 2.5 NA 0.6 NA NA
MCCB feeders
8 415 cables for 2.5 15 0.6 NA NA
MCCB fed
motors
0 17-11-99 TSM -
REV DATE PRPD CHKD APPRD REV DATE PRPD CHKD APPRD
FACT ENGINEERING AND DESIGN ORGANISATION
CUSTOMER : NFL UCSA Ref. No.8073-ECC-001 Rev/
PLANT LOCATION : NANGAL INDIA JOB No: 8073 Sheet 2 of 4
PROJECT : NANGAL UREA EXPANSION CAPACITY INCREASE BY 450 MTPD
 8074-13-CA-05
CALCULATION CABLE SIZING CALCULATION
SHEETS SHEET 3 OF 4

3.0 CALCULATION

3.1 The cable sizing calculation is done for each power cable by a computer program. The details of each
power cable can be obtained form the Cable schedules with the help of Cable Nos. indicated. Following
sub calculations are involved in the program.

3.2 The Full Load Current (FLC) in the program is calculated using the following equations,

a) For 3 Phase Motors, FLC = Motor kW *1000/3/Voltage/Efficiency/Power Factor

b) For 1 Phase Motors, FLC = Motor kW *1000/Voltage/Efficiency/Power Factor

c) For 3 Phase feeders, FLC = Feeder Rating in Amps * % Loading

3.3 The cable rated current, 1-sec rating, resistance and reactance are obtained from cable data published by
manufacturers.

3.4 The derating factor =FLC/No. of runs of cable/Rated cable current

3.5 If no. of runs of cables are more than one the voltage drop and derating factor are pro rata adjusted.

3.6 The cable size suitable for a given fault current is determined by the relation,

Size in [Link] = If*t………………………………………..(3)

k
Where If = Fault current in kA
t = Withstand time in s
k = constant

From (3) above, 1 sec rating of a cable, I1 = [Link]*k/1

= [Link]*k……….(4)

From (3) & (4) above t = [Link]*k/ If

= I1/ If

Therefore withstand time, t = (I1/ If )2

ie. Fault withstand time Tsc = (one sec rating/Fault kA) 2

3.7 The voltage drop, derating factor and withstand time for the cable size selected are indicated in the
calculation sheets annexed. It can be seen that these values are within the permissible limits furnished in
Table-1.

0 17-11-99 TSM -
REV DATE PRPD CHKD APPRD REV DATE PRPD CHKD APPRD
FACT ENGINEERING AND DESIGN ORGANISATION
CUSTOMER : NFL UCSA Ref. No.8073-ECC-001 Rev/
PLANT LOCATION : NANGAL INDIA JOB No: 8073 Sheet 3 of 4
PROJECT : NANGAL UREA EXPANSION CAPACITY INCREASE BY 450 MTPD
 4.0 Annexures 8074-13-CA-05
CALCULATION CABLEtoSIZING CALCULATION
4.1 Calculation Sheets as Annexure-1
SHEETS Annexure-5
SHEET 4 OF 4

0 17-11-99 TSM -
REV DATE PRPD CHKD APPRD REV DATE PRPD CHKD APPRD
FACT ENGINEERING AND DESIGN ORGANISATION
CUSTOMER : NFL UCSA Ref. No.8073-ECC-001 Rev/
PLANT LOCATION : NANGAL INDIA JOB No: 8073 Sheet 4 of 4
PROJECT : NANGAL UREA EXPANSION CAPACITY INCREASE BY 450 MTPD