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INDEX SHEET
SHEET NO. TITLE 0 1
1 COVER SHEET 4-Jun-2011 29-Jun-2011
2 INDEX SHEET 4-Jun-2011 29-Jun-2011
3 REVISION RECORD SHEET 4-Jun-2011 29-Jun-2011
4 DESIGN BASIS 4-Jun-2011 29-Jun-2011
5 DESIGN BASIS 4-Jun-2011 29-Jun-2011
6 DESIGN BASIS 4-Jun-2011 29-Jun-2011
7 DESIGN BASIS 4-Jun-2011 29-Jun-2011
8 DESIGN BASIS 4-Jun-2011 29-Jun-2011
9 DESIGN BASIS 4-Jun-2011 29-Jun-2011
10 3/6.6kV CABLE DATA 4-Jun-2011 29-Jun-2011
11 CALCULATION SHEET 4-Jun-2011 29-Jun-2011

12 CALCULATION SHEET 4-Jun-2011 29-Jun-2011

13 CALCULATION SHEET 4-Jun-2011 29-Jun-2011

14 CALCULATION SHEET 4-Jun-2011 29-Jun-2011

15 CALCULATION SHEET 4-Jun-2011 29-Jun-2011

16 CALCULATION SHEET 4-Jun-2011 29-Jun-2011

17 CALCULATION SHEET 4-Jun-2011 29-Jun-2011

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REVISION RECORD SHEET

REV. NO. PURPOSE LIST OF PAGES OF UPDATED / MODIFIED SECTIONS, IF ANY
0 ISSUED FOR REFERENCE
1 RE -ISSUED FOR REFERENCE
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1.0 PURPOSE

The cable selecton basis calculations are carried out to calculate the size for cables (6.6kV& LV power cables
required to be installed for HMDS Station in SMS - II
This document provides the guidelines to determine the operating limits of cables enforced by voltage drop,
conductor ampacity, derating current considerations and short circuit withstand capacity.

2.0 CONDUCTOR SIZING CRITERIA

MV Cables have been sized based on the following criteria

a. Current carrying capacity of conductor (Ampacity)
b. Voltage drop calculations
c. Short circuit withstand capacity

LV & DC Cables have been sized based on the following criteria

a. Current carrying capacity of conductor (Ampacity)
b. Voltage drop calculations

2.1 REFFERENCE DOCUMENTS

Document No. Description

GS-03 General Specification for Electrical System
7-0-05-36-29-1534 Electrical Power Cable Schedule
Manufacturers Catalogue Havells Cables

2.2 APPLICATION STANDARDS

IEC 60092-352 Choice and installation of cables for low-voltage power systems
IEC 60228 Specification for the Conductors of insuated Cable
IEC 60287 Calculation of the continuous current rating of cable (100% load factor)
IEC 60331 Fire-resisting characteristics of electrical cables
IEC 60502, Edition 2005-2 Specification for the power cables (1kV to 30kV) with extruded insulation
IEC 60815 Electrical test methods for electrical cables

2.3 DESIGN CONDITION

Air ambient temperature : 50 C

Ambient ground temperature : 30 C
Soil thermal resistivity : 1 K.m/W
Depth of laying of underground cable : 0.67 m

3.0 CURRENT CARRYING CAPACITY OF CONDUCTOR (AMPACITY)

Ampacity of power cable is obtained from cable catalogues for approved manufacturer

These data are further derated for ambient temperature rise, method of cable grouping & installation.
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3.1 DERATING FACTOR (D.F)

The cables shall be installed in cable trench,duct and cable trays.
Derating factor is calculated for all Cables as per the following

A) DERATING FACTOR - TEMPERATURE (DF1)

Table A.1 Derating factor for Ambient air temperature other than 30 C(Refer Table B.10 of IEC 60502-2:2005)

Maximum conductor Ambient air temperature deg C

temperature deg C 20 25 30 35 40 42 45 50 55 60
90 1.08 1.02 1.00 0.96 0.91 0.89 0.87 0.82 0.76 0.71

Table A.2 Derating factor for Ambient ground temperature other than 20 C(Refer Table B.11 of IEC 60502-2:2005)

Maximum conductor Ambient ground temperature deg C

temperature deg C 10 15 20 25 30 35 40 45 50
90 1.07 1.04 1.00 0.96 0.93 0.89 0.85 0.80 0.76

B) DERATING FACTOR - GROUPING (DF2)

Three Core Cables

Number of circuits 2 3 4 5 6 7 8 9

Rating Factors 0.8 0.7 0.65 0.6 0.57 0.54 0.52 0.5
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Table B.5 Group derating factors for more than one circuit of single core cables in free air
No. of No. of three phase circuits
trays 1 2 3
For horizontal
1 1.00 0.97 0.96
formation
2 0.98 0.93 0.89 (Refer Table B.23 of IEC 60502-2:2005)
3 0.97 0.90 0.86
1 1.00 1.00 1.00
For trefoil
2 0.97 0.95 0.93
formation
3 0.96 0.94 0.90

Table B.6 Group derating factors for more than one multi core cables in free air touching

No. of No. of cables

trays 1 2 3 4 6 9
1 1.00 0.87 0.82 0.80 0.79 0.78
2 1.00 0.86 0.80 0.78 0.76 0.73 (Refer Table B.22 of IEC 60502-2:2005)
3 1.00 0.85 0.79 0.76 0.73 0.70

C) DERATING FACTOR - SOIL THERMAL RESISTIVITY (for underground cables) (DF3)

Table C.1 Derating factors for soil thermal resistivities other than 1.5K.m/W for direct buried single core cables
Conductor Values of soil thermal resistivity (Km/W)
size 0.7 0.8 0.9 1.0 1.5 2.0 2.5 3.0
16 1.29 1.24 1.19 1.150 1.000 0.890 0.820 0.750
25 1.3 1.25 1.20 1.160 1.000 0.890 0.810 0.750
35 1.3 1.25 1.21 1.160 1.000 0.890 0.810 0.750
50 1.32 1.26 1.21 1.160 1.000 0.890 0.810 0.740
(Refer Table B.14 of
70 1.33 1.27 1.22 1.170 1.000 0.890 0.810 0.740
IEC 60502-2:2005)
95 1.34 1.28 1.22 1.180 1.000 0.890 0.800 0.740
120 1.34 1.28 1.22 1.180 1.000 0.880 0.800 0.740
150 1.35 1.28 1.23 1.180 1.000 0.880 0.800 0.740
185 1.35 1.29 1.23 1.180 1.000 0.880 0.800 0.740
240 1.36 1.29 1.23 1.180 1.000 0.880 0.800 0.730
300 1.36 1.3 1.24 1.190 1.000 0.880 0.800 0.730
400 1.37 1.3 1.24 1.190 1.000 0.880 0.790 0.730

Table C.2 Derating factors for soil thermal resistivities other than 1.5K.m/W for single core cables in buried ducts
Conductor Values of soil thermal resistivity (Km/W)
size 0.7 0.8 0.9 1.0 1.5 2.0 2.5 3.0
16 1.2 1.17 1.14 1.110 1.000 0.920 0.850 0.790
25 1.21 1.17 1.14 1.120 1.000 0.910 0.850 0.790
35 1.21 1.18 1.15 1.120 1.000 0.910 0.840 0.790
50 1.21 1.18 1.15 1.120 1.000 0.910 0.840 0.780
(Refer Table B.15 of
70 1.22 1.19 1.15 1.120 1.000 0.910 0.840 0.780
IEC 60502-2:2005)
95 1.23 1.19 1.16 1.130 1.000 0.910 0.840 0.780
120 1.23 1.20 1.16 1.130 1.000 0.910 0.840 0.780
150 1.24 1.20 1.16 1.130 1.000 0.910 0.830 0.780
185 1.24 1.20 1.17 1.130 1.000 0.910 0.830 0.780
240 1.25 1.21 1.17 1.140 1.000 0.900 0.830 0.770
300 1.25 1.21 1.17 1.140 1.000 0.900 0.830 0.770
400 1.25 1.21 1.17 1.140 1.000 0.900 0.830 0.770
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Table C.3 Derating factors for soil thermal resistivities other than 1.5K.m/W for direct buried 3 core cable

Conductor Values of soil thermal resistivity (Km/W)

size 0.7 0.8 0.9 1.0 1.5 2.0 2.5 3.0
16 1.23 1.19 1.16 1.130 1.000 0.910 0.840 0.780
25 1.24 1.20 1.16 1.130 1.000 0.910 0.840 0.780
35 1.25 1.21 1.17 1.130 1.000 0.910 0.830 0.780
50 1.25 1.21 1.17 1.140 1.000 0.910 0.830 0.770
(Refer Table B.16 of
70 1.26 1.21 1.18 1.140 1.000 0.900 0.830 0.770
IEC 60502-2:2005)
95 1.26 1.22 1.18 1.140 1.000 0.900 0.830 0.770
120 1.26 1.22 1.18 1.140 1.000 0.900 0.830 0.770
150 1.27 1.22 1.18 1.150 1.000 0.900 0.830 0.770
185 1.27 1.23 1.18 1.150 1.000 0.900 0.830 0.770
240 1.28 1.23 1.19 1.150 1.000 0.900 0.830 0.770
300 1.28 1.23 1.19 1.150 1.000 0.900 0.820 0.770
400 1.28 1.23 1.19 1.150 1.000 0.900 0.820 0.760

Table C.4 Derating factors for soil thermal resistivities other than 1.5K.m/W for 3 core cable in ducts

Conductor Values of soil thermal resistivity (Km/W)

size 0.7 0.8 0.9 1.0 1.5 2.0 2.5 3.0
16 1.12 1.11 1.09 1.080 1.000 0.940 0.890 0.840
25 1.14 1.12 1.10 1.080 1.000 0.940 0.890 0.840
35 1.14 1.12 1.10 1.080 1.000 0.940 0.880 0.840
50 1.14 1.12 1.10 1.080 1.000 0.940 0.880 0.840
(Refer Table B.17 of
70 1.15 1.13 1.11 1.090 1.000 0.940 0.880 0.830
IEC 60502-2:2005)
95 1.15 1.13 1.11 1.090 1.000 0.940 0.880 0.830
120 1.15 1.13 1.11 1.090 1.000 0.930 0.880 0.830
150 1.16 1.13 1.11 1.090 1.000 0.930 0.880 0.830
185 1.16 1.14 1.11 1.090 1.000 0.930 0.870 0.830
240 1.16 1.14 1.12 1.100 1.000 0.930 0.870 0.820
300 1.17 1.14 1.12 1.100 1.000 0.930 0.870 0.820
400 1.17 1.14 1.12 1.100 1.000 0.920 0.860 0.810
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D) DERATING FACTOR - DEPTH OF LAYING (for underground cables) (DF4)

Table D.1 Derating Factors for depth of laying for direct buried cables

Single core cables Three

Depth of laying
Normal conductor size core
(m)
185mm2 > 185mm2 cables
0.50 1.04 1.06 1.04
0.60 1.02 1.04 1.03
0.80 1.00 1.00 1.00
1.00 0.98 0.97 0.98 (Refer Table B.12 of IEC 60502-2:2005)
1.25 0.96 0.95 0.96
1.50 0.95 0.93 0.95
1.75 0.94 0.91 0.94
2.00 0.93 0.90 0.93
2.50 0.91 0.88 0.91
3.00 0.90 0.86 0.90

Table D.2 Derating Factors for depth of laying for direct buried cables in ducts.

Single core cables Three

Depth of laying
Normal conductor size core
(m)
185mm2 > 185mm2 cables
0.50 1.04 1.05 1.03
0.60 1.02 1.03 1.02
0.80 1.00 1.00 1.00
1.00 0.98 0.97 0.99 (Refer Table B.13 of IEC 60502-2:2005)
1.25 0.96 0.95 0.97
1.50 0.95 0.93 0.96
1.75 0.94 0.92 0.95
2.00 0.93 0.91 0.94
2.50 0.91 0.89 0.93
3.00 0.90 0.88 0.92

Hence the current carrying capacity of the selected conductor after derated rating will be as follow,
ID = DF1xDF2xDF3xDF4xIxn For underground cables
ID = DF1xDF2xIxn For cables in air
where
ID is derated current rating
I is current carrying capacity of cable
n is number of runs of cable

3.2 VOLTAGE DROP

The cable size selected is checked against voltage drop limit values.
1) Voltage drop of three phase power cable are given as follows

VD 1)
= 1.732 x IL x (R Cos + X Sin) x L/n
(VD2)
)r = 1.732 x ILx (R Cosr + X Sinr) x L/n
(VD3)
)s = 1.732 x ILS x (R Coss + X Sins) x L/n
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2) Voltage drop of single phase power cable are given as follows

VD 1)
= 2 x IL x (R Cos + X Sin) x L/n
(VD2)
)r = 2 x ILx (R Cosr + X Sinr) x L/n
(VD3)
)s = 2 x ILS x (R Coss + X Sins) x L/n

3) Voltage drop of DC power cable is given as follow

VD = 2 x IL x R x L/n
(VD)r = 2 x IL x R x L/n
(VD)s = 2 x ILs x R x L/n
Where,
VD Voltage drop in volts
(VD)r Voltage drop in volts when motor running
(VD)s Voltage drop in volts at starting of motor
IL Full Load Current in amps when motor running
ILS Starting current in amps
R Resistance in ohm/km (As per Vendor data)
X Reactance in ohm/km (As per Vendor data)
L Length in km
n Number of runs
Cos Power Factor
Cosr Running Power Factor
Coss Starting Power Factor

Notes:
1. Starting power factor i.e. cos s is considered as 0.3.
2. Starting current is considered as six times full load current for motors using DOL starter
3. As per General Specification for Electrical System (GS-03) page no. 07 the maximum allowable
voltage drop across the cable in percent of system nominal line to line voltage shall be as follows
LTSS to Motor 6%
LTSS to MCC/PDB/MLDB if in the same building 2%
MCC to motor for aboe case 4%
LTSS to MCC/PDB/MLDB if in the same building 3%
Motors (Running) 6%
Motors (Starting) 15%

3.3 SHORT CIRCUIT WITHSTAND CAPACITY

The cross sectional area calculated shall not be less than the value determined by the criteria

I2SCmin x tCB < K2 x S2min

Smin > (I2SCmin x tCB) (K2)

Smin Minimum cross section area required to withstand the short circuit current (mm2)
K factor (K= 94 for AL XLPE cables, Refer IEC 60724:1984)
tCB Circuit breaker fault clearing time (sec), 0.35 sec. (AS per GS of Electrical system)
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3/6.6 kV THREE CORE CABLE DATA (Havells)

Conductor Aluminium /Annealed plain Copper Standed compacted circular conductor

confirm to BS 6360 and IEC 60228, Class
Conductor Screen semi-conducting layer over conductor
Insulation Extruded Cross-Linked Polyethylene (XLPE) to BS 5469
Insulation Screen Extruded semi-conducting XLPE layer with semi-conducting tape and overlapping
Copper tape screen over the core
Core Identification Red, Yellow and Blue
The three power core shall be laid up with non-hygroscopic fillers in round shape
and a suitable binder tape shall be applied helically over the cabled cores
Inner sheath (Bedding) Extruded layer of flame retardant black PVC compound with oxygen index
not less than 30, temperature index not less than 300 C and complying with
Class ST2 of IEC 60502
Armour Single layer of Galvanised round Steel Wires
Over sheath Flame retardant PVC complying with ST2 of IEC 60502
Over sheath colour Red

Conductor screen, insulation and insulation screen shall be extruded simultaneously in one operation using the triple
extrution process. The insulation layer shall be distinguishable and easily strippable from the semi-conducting layers
without the need for special tools or heat sources

90
Conductor maximum Temperature C
50
Ambient Air Temperature C
20
Ground Temperature C
Depth of Laying in ground 0.8 m
Thermal resistivity of soil 1.5 K m/W

Table T.2 : Three Core Cable Technical Data (Based on above condition)

(Refer the Cable catalogue attached )

Current Current
Current Max. Rac Isc for 1 sec
Cable Rating ID Rating ID Reactance
Rating ID at 90 C
Size (in (in PE at 50 Hz (X)
(in Air) (R)
Ground) Duct) Cu Al
2
(mm ) (amps) (amps) (amps) (/Km) (/Km) kA kA
16 97 88 71 1.47 0.10 2.29 1.5
25 105 95 82 1.54 0.13 3.6 2.4
35 125 115 97 1.11 0.12 5.0 3.3
50 150 130 115 0.82 0.11 7.2 4.7
70 190 160 140 0.57 0.11 10.0 6.6
95 230 190 165 0.41 0.10 13.6 8.9
120 260 220 190 0.32 0.10 17.2 11.3
150 295 245 210 0.26 0.10 21.5 14.1
185 335 275 240 0.21 0.09 26.5 17.4
240 395 315 275 0.16 0.09 34.3 22.6
300 450 355 310 0.13 0.09 42.9 28.2
400 520 400 350 0.10 0.09 57.2 37.6
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C. 6.6 kV SYSTEM CABLE SIZING CALCULATION

1. Short Circuit Withstand Capability (6.6kV):

Short Circuit Current of incoming bus = 31.5 kA

Formula for finding the minimum cable size to withstand the short circuit current is
2 2
Smin > (I SCmin x tCB)/( K)
Where
Iscmin = 31.5 kA
K = factor (K= 94 for Al XLPE cables, Refer IEC 60724:1984)
tCB = Circuit breaker fault clearing time, 0.35 sec. (AS per GS of Electrical system)
Smin = 198.25 Sq mm
Based on the above calculation, minimum cable size shall be 240 sq.mm for 6.6 kV cables
However the above cable size has to be verified for Current carrying capacity and Voltage drop limit.
2. CURRENT CARRYING CAPACITY AND VOLTAGE DROP CALCULATION :
1) EQUIPMENT NAME:. (VCB Main to VCB Transformer 1)

KW Rating 1392 KW (1740kVA x 0.8 P.F)

Cable Length 800 m
FLC 152.21 Amps (as per Motor vendor data)
Voltage Rating 6.6 kV
Power Factor(cos) 0.8
Derating Factor(DF1) 0.82 (Refer Table A.1 in sheet 5)
Derating Factor(DF2) 0.80 (Refer table B in sheet 5)
Derating Factor(DF3) 1.00 (Refer table C.3 in sheet 7) N/A
Derating Factor(DF4) 1.00 (Refer table D.1 in sheet 8) N/A
Derating Factor = 0.82x0.8x1x1 = 0.65

Cable Type Al-SWA-XLPE-FRPVC

: Multi Core Armoured cable.

Cable Sizing is done and result is tabulated as below

Voltage Drop
Current
Derated Rac at
Cable (in air) Reactance Actual %
No of Current 90 C
Size vendor at 50 Hz (X) voltage Voltage
Sl. No. runs ID (R)
data drop drop
(n)
2
(mm ) Amps Amps /Km /Km Volts 3% Max

1 1 185 335 217.75 0.2100 0.093 47.201 0.715

2 1 240 395 256.75 0.1600 0.090 38.385 0.582
3 1 300 450 292.50 0.1300 0.090 33.324 0.505

Based On above calculation results it is recommended to use 1-3CX 240 Sq mm cable.

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C. 6.6 kV SYSTEM CABLE SIZING CALCULATION

1. Short Circuit Withstand Capability (6.6kV):
Short Circuit Current of incoming bus = 31.5 kA
Formula for finding the minimum cable size to withstand the short circuit current is
2 2
Smin > (I SCmin x tCB)/( K)
Where
Iscmin = 31.5 kA
K = factor (K= 94 for Al XLPE cables, Refer IEC 60724:1984)
tCB = Circuit breaker fault clearing time, 0.35 sec. (AS per GS of Electrical system)
Smin = 198.25 Sq mm
Based on the above calculation, minimum cable size shall be 240 sq.mm for 6.6 kV cables
However the above cable size has to be verified for Current carrying capacity and Voltage drop limit.
2. CURRENT CARRYING CAPACITY AND VOLTAGE DROP CALCULATION :
1) EQUIPMENT NAME:. ( VCB Transformer 1 to Transformer 1)

KW Rating 1392 KW (1740kVA x 0.8 P.F)

Cable Length 15 m
FLC 152.21 Amps (as per Motor vendor data)
Voltage Rating 6.6 kV
Power Factor(cos) 0.8
Derating Factor(DF1) 0.82 (Refer Table A.1 in sheet 5)
Derating Factor(DF2) 0.80 (Refer table B in sheet 5)
Derating Factor(DF3) 1.00 (Refer table C.3 in sheet 7) N/A
Derating Factor(DF4) 1.00 (Refer table D.1 in sheet 8) N/A
Derating Factor = 0.82x0.8x1x1 = 0.65

Cable Type :
Al-SWA-XLPE-FRPVC Multi Core Armoured cable.

Cable Sizing is done and result is tabulated as below

Voltage Drop
Current
Derated Rac at
Cable (in air) Reactance Actual %
No of Current 90 C
Size vendor at 50 Hz (X) voltage Voltage
Sl. No. runs ID (R)
data drop drop
(n)

(mm2) Amps Amps /Km /Km Volts 3% Max

1 1 185 335 217.75 0.2100 0.093 0.885 0.013

2 1 240 395 256.75 0.1600 0.090 0.720 0.011
3 1 300 450 292.50 0.1300 0.090 0.625 0.009

Based On above calculation results it is recommended to use 2-3CX 240 Sq mm cable.

TITLE DOC. No.
HT CABLE SIZING CALCULATION 0-
PROJECT DESCRIPTION DOC. No. SHEET REV
HOT METAL DESULPHURISATION STATION IN SMS - II - 13 OF 17 1
VENDOR PURCHASE ORDER No. REQUISITION No. SPECIFICATION No.
- - - -
CLIENT NAME REV No. BY DATE CKD DATE APP. DATE DESCRIPTION
TATA PROJECTS 0 MR 4-Jun-11 NP 4-Jun-11 MSR 4-Jun-11 ISSUED FOR REFERANCE
CLIENT DOC NO. 1 NP 29-Jun-11 ECK 29-Jun-11 MSR 29-Jun-11 ISSUED FOR REFERANCE
-
ORIGINATOR ORIG. DATE
MR 4-Jun-11

C. 6.6 kV SYSTEM CABLE SIZING CALCULATION

1. Short Circuit Withstand Capability (6.6kV):

Short Circuit Current of incoming bus = 31.5 kA

Formula for finding the minimum cable size to withstand the short circuit current is
Smin > (I2SCmin x tCB)/( K2)
Where
Iscmin = 31.5 kA
K = factor (K= 94 for Al XLPE cables, Refer IEC 60724:1984)
tCB = Circuit breaker fault clearing time, 0.35 sec. (AS per GS of Electrical system)
Smin = 198.25 Sq mm

Based on the above calculation, minimum cable size shall be 240 sq.mm for 6.6 kV cables
However the above cable size has to be verified for Current carrying capacity and Voltage drop limit.

2. CURRENT CARRYING CAPACITY AND VOLTAGE DROP CALCULATION :

1) EQUIPMENT NAME:. (Transformer 1 to VFD1)

KW Rating 232 KW (290kVA x 0.8 P.F)

Cable Length 25 m
FLC 87.21 Amps (as per Motor vendor data)
Voltage Rating 1.92 kV
Power Factor(cos) 0.8
Derating Factor(DF1) 0.82 (Refer Table A.1 in sheet 5)
Derating Factor(DF2) 0.80 (Refer table B in sheet 5)
Derating Factor(DF3) 1.00 (Refer table C.3 in sheet 7) N/A
Derating Factor(DF4) 1.00 (Refer table D.1 in sheet 8) N/A
Derating Factor = 0.82x0.8x1x1 = 0.65

Cable Type :
Al-SWA-XLPE-FRPVC Multi Core Armoured cable.

Cable Sizing is done and result is tabulated as below

Current Voltage Drop

Derated Rac at
Cable (in air) Reactance Actual %
No of Current 90 C
Size vendor at 50 Hz (X) voltage Voltage
Sl. No. runs ID (R)
data drop drop
(n)
(mm2) Amps Amps /Km /Km Volts 3% Max
1 1 185 335 217.75 0.2100 0.093 0.845 0.044
2 1 240 395 256.75 0.1600 0.090 0.687 0.036
3 1 300 450 292.50 0.1300 0.090 0.597 0.031

Based On above calculation results it is recommended to use 6-3CX 240 Sq mm cable.

TITLE DOC. No.
HT CABLE SIZING CALCULATION -
PROJECT DESCRIPTION DOC. No. SHEET REV
HOT METAL DESULPHURISATION STATION IN SMS - II - 14 OF 17 1
VENDOR PURCHASE ORDER No. REQUISITION No. SPECIFICATION No.
- - - -
CLIENT NAME REV No. BY DATE CKD DATE APP. DATE DESCRIPTION
TATA PROJECTS 0 MR 4-Jun-11 NP 4-Jun-11 MSR 4-Jun-11 ISSUED FOR REFERANCE
CLIENT DOC NO. 1 NP 29-Jun-11 ECK 29-Jun-11 MSR 29-Jun-11 ISSUED FOR REFERANCE
-
ORIGINATOR ORIG. DATE
MR 4-Jun-11

C. 6.6 kV SYSTEM CABLE SIZING CALCULATION

1. Short Circuit Withstand Capability (6.6kV):

Short Circuit Current of incoming bus = 31.5 kA

Formula for finding the minimum cable size to withstand the short circuit current is
Smin > (I2SCmin x tCB)/( K2)
Where
Iscmin = 31.5 kA
K = factor (K= 94 for Al XLPE cables, Refer IEC 60724:1984)
tCB = Circuit breaker fault clearing time, 0.35 sec. (AS per GS of Electrical system)
Smin = 198.25 Sq mm

Based on the above calculation, minimum cable size shall be 240 sq.mm for 6.6 kV cables
However the above cable size has to be verified for Current carrying capacity and Voltage drop limit.

2. CURRENT CARRYING CAPACITY AND VOLTAGE DROP CALCULATION :

1) EQUIPMENT NAME:. (VFD1 to VCB Motor 1)

KW Rating 990 KW (Refer SLD. Doc. No. 7-0-05-36-29-1500)

Cable Length 30 m
FLC 108.26 Amps (as per Motor vendor data)
Voltage Rating 6.6 kV
Power Factor(cos) 0.8
Derating Factor(DF1) 0.82 (Refer Table A.1 in sheet 5)
Derating Factor(DF2) 0.80 (Refer table B in sheet 5)
Derating Factor(DF3) 1.00 (Refer table C.3 in sheet 7) N/A
Derating Factor(DF4) 1.00 (Refer table D.1 in sheet 8) N/A
Derating Factor = 0.82x0.8x1x1 = 0.65

Cable Type :
Al-SWA-XLPE-FRPVC Multi Core Armoured cable.

Cable Sizing is done and result is tabulated as below

Current Voltage Drop

Derated Rac at
Cable (in air) Reactance Actual %
No of Current 90 C
Size vendor at 50 Hz (X) voltage Voltage
Sl. No. runs ID (R)
data drop drop
(n)
(mm2) Amps Amps /Km /Km Volts 3% Max
1 1 185 335 217.75 0.2100 0.093 1.259 0.019
2 1 240 395 256.75 0.1600 0.090 1.024 0.016
3 1 300 450 292.50 0.1300 0.090 0.889 0.013

Based On above calculation results it is recommended to use 1-3CX 240 Sq mm cable.

TITLE DOC. No.
HT CABLE SIZING CALCULATION -
PROJECT DESCRIPTION DOC. No. SHEET REV
HOT METAL DESULPHURISATION STATION IN SMS - II - 15 OF 17 1
VENDOR PURCHASE ORDER No. REQUISITION No. SPECIFICATION No.
- - - -
CLIENT NAME REV No. BY DATE CKD DATE APP. DATE DESCRIPTION
TATA PROJECTS 0 MR 4-Jun-11 NP 4-Jun-11 MSR 4-Jun-11 ISSUED FOR REFERANCE
CLIENT DOC NO. 1 NP 29-Jun-11 ECK 29-Jun-11 MSR 29-Jun-11 ISSUED FOR REFERANCE
-
ORIGINATOR ORIG. DATE
MR 4-Jun-11

C. 6.6 kV SYSTEM CABLE SIZING CALCULATION

1. Short Circuit Withstand Capability (6.6kV):

Short Circuit Current of incoming bus = 31.5 kA

Formula for finding the minimum cable size to withstand the short circuit current is
Smin > (I2SCmin x tCB)/( K2)
Where
Iscmin = 31.5 kA
K = factor (K= 94 for Al XLPE cables, Refer IEC 60724:1984)
tCB = Circuit breaker fault clearing time, 0.35 sec. (AS per GS of Electrical system)
Smin = 198.25 Sq mm

Based on the above calculation, minimum cable size shall be 240 sq.mm for 6.6 kV cables
However the above cable size has to be verified for Current carrying capacity and Voltage drop limit.

2. CURRENT CARRYING CAPACITY AND VOLTAGE DROP CALCULATION :

1) EQUIPMENT NAME:. (VCB Transformer 1 to VCB Bypass 1)

KW Rating 990 KW (Refer SLD. Doc. No. 7-0-05-36-29-1500)

Cable Length 35 m
FLC 108.26 Amps (as per Motor vendor data)
Voltage Rating 6.6 kV
Power Factor(cos) 0.8
Derating Factor(DF1) 0.82 (Refer Table A.1 in sheet 5)
Derating Factor(DF2) 0.80 (Refer table B in sheet 5)
Derating Factor(DF3) 1.00 (Refer table C.3 in sheet 7) N/A
Derating Factor(DF4) 1.00 (Refer table D.1 in sheet 8) N/A
Derating Factor = 0.82x0.8x1x1 = 0.65

Cable Type :
Al-SWA-XLPE-FRPVC Multi Core Armoured cable.

Cable Sizing is done and result is tabulated as below

Current Voltage Drop

Derated Rac at
Cable (in air) Reactance Actual %
No of Current 90 C
Size vendor at 50 Hz (X) voltage Voltage
Sl. No. runs ID (R)
data drop drop
(n)
(mm2) Amps Amps /Km /Km Volts 3% Max
1 1 185 335 217.75 0.2100 0.093 1.469 0.022
2 1 240 395 256.75 0.1600 0.090 1.194 0.018
3 1 300 450 292.50 0.1300 0.090 1.037 0.016

Based On above calculation results it is recommended to use 1-3CX 240 Sq mm cable.

TITLE DOC. No.
HT CABLE SIZING CALCULATION -
PROJECT DESCRIPTION DOC. No. SHEET REV
HOT METAL DESULPHURISATION STATION IN SMS - II - 16 OF 17 1
VENDOR PURCHASE ORDER No. REQUISITION No. SPECIFICATION No.
- - - -
CLIENT NAME REV No. BY DATE CKD DATE APP. DATE DESCRIPTION
TATA PROJECTS 0 MR 4-Jun-11 NP 4-Jun-11 MSR 4-Jun-11 ISSUED FOR REFERANCE
CLIENT DOC NO. 1 NP 29-Jun-11 ECK 29-Jun-11 MSR 29-Jun-11 ISSUED FOR REFERANCE
-
ORIGINATOR ORIG. DATE
MR 4-Jun-11

C. 6.6 kV SYSTEM CABLE SIZING CALCULATION

1. Short Circuit Withstand Capability (6.6kV):

Short Circuit Current of incoming bus = 31.5 kA

Formula for finding the minimum cable size to withstand the short circuit current is
Smin > (I2SCmin x tCB)/( K2)
Where
Iscmin = 31.5 kA
K = factor (K= 94 for Al XLPE cables, Refer IEC 60724:1984)
tCB = Circuit breaker fault clearing time, 0.35 sec. (AS per GS of Electrical system)
Smin = 198.25 Sq mm

Based on the above calculation, minimum cable size shall be 240 sq.mm for 6.6 kV cables
However the above cable size has to be verified for Current carrying capacity and Voltage drop limit.

2. CURRENT CARRYING CAPACITY AND VOLTAGE DROP CALCULATION :

1) EQUIPMENT NAME:. (VCB Bypass 1 to VCB Motor 1)

KW Rating 990 KW (Refer SLD. Doc. No. 7-0-05-36-29-1500)

Cable Length 10 m
FLC 108.26 Amps (as per Motor vendor data)
Voltage Rating 6.6 kV
Power Factor(cos) 0.8
Derating Factor(DF1) 0.82 (Refer Table A.1 in sheet 5)
Derating Factor(DF2) 0.80 (Refer table B in sheet 5)
Derating Factor(DF3) 1.00 (Refer table C.3 in sheet 7) N/A
Derating Factor(DF4) 1.00 (Refer table D.1 in sheet 8) N/A
Derating Factor = 0.82x0.8x1x1 = 0.65

Cable Type :
Al-SWA-XLPE-FRPVC Multi Core Armoured cable.

Cable Sizing is done and result is tabulated as below

Current Voltage Drop

Derated Rac at
Cable (in air) Reactance Actual %
No of Current 90 C
Size vendor at 50 Hz (X) voltage Voltage
Sl. No. runs ID (R)
data drop drop
(n)
(mm2) Amps Amps /Km /Km Volts 3% Max
1 1 185 335 217.75 0.2100 0.093 0.420 0.006
2 1 240 395 256.75 0.1600 0.090 0.341 0.005
3 1 300 450 292.50 0.1300 0.090 0.296 0.004

Based On above calculation results it is recommended to use 1-3CX 240 Sq mm cable.

TITLE DOC. No.
HT CABLE SIZING CALCULATION -
PROJECT DESCRIPTION DOC. No. SHEET REV
HOT METAL DESULPHURISATION STATION IN SMS - II - 17 OF 17 1
VENDOR PURCHASE ORDER No. REQUISITION No. SPECIFICATION No.
- - - -
CLIENT NAME REV No. BY DATE CKD DATE APP. DATE DESCRIPTION
TATA PROJECTS 0 MR 4-Jun-11 NP 4-Jun-11 MSR 4-Jun-11 ISSUED FOR REFERANCE
CLIENT DOC NO. 1 NP 29-Jun-11 ECK 29-Jun-11 MSR 29-Jun-11 ISSUED FOR REFERANCE
-
ORIGINATOR ORIG. DATE
MR 4-Jun-11

C. 6.6 kV SYSTEM CABLE SIZING CALCULATION

1. Short Circuit Withstand Capability (6.6kV):

Short Circuit Current of incoming bus = 31.5 kA

Formula for finding the minimum cable size to withstand the short circuit current is
Smin > (I2SCmin x tCB)/( K2)
Where
Iscmin = 31.5 kA
K = factor (K= 94 for Al XLPE cables, Refer IEC 60724:1984)
tCB = Circuit breaker fault clearing time, 0.35 sec. (AS per GS of Electrical system)
Smin = 198.25 Sq mm

Based on the above calculation, minimum cable size shall be 240 sq.mm for 6.6 kV cables
However the above cable size has to be verified for Current carrying capacity and Voltage drop limit.

2. CURRENT CARRYING CAPACITY AND VOLTAGE DROP CALCULATION :

1) EQUIPMENT NAME:. (VCB Motor 1 to Motor 1)

KW Rating 990 KW ( Refer SLD. Doc. No. 7-0-05-36-29-1500)

Cable Length 100 m
FLC 108.26 Amps (as per Motor vendor data)
Voltage Rating 6.6 kV
Power Factor(cos) 0.8
Derating Factor(DF1) 0.82 (Refer Table A.1 in sheet 5)
Derating Factor(DF2) 0.80 (Refer table B in sheet 5)
Derating Factor(DF3) 1.00 (Refer table C.3 in sheet 7) N/A
Derating Factor(DF4) 1.00 (Refer table D.1 in sheet 8) N/A
Derating Factor = 0.82x0.8x1x1 = 0.65

Cable Type :
Al-SWA-XLPE-FRPVC Multi Core Armoured cable.

Cable Sizing is done and result is tabulated as below

Current Voltage Drop

Derated Rac at
Cable (in air) Reactance Actual %
No of Current 90 C
Size vendor at 50 Hz (X) voltage Voltage
Sl. No. runs ID (R)
data drop drop
(n)
(mm2) Amps Amps /Km /Km Volts 3% Max
1 1 185 335 2211.00 0.2100 0.093 4.196 0.064
2 1 240 395 2607.00 0.1600 0.090 3.413 0.052
3 1 300 450 2970.00 0.1300 0.090 2.963 0.045

Based On above calculation results it is recommended to use 1-3CX 240 Sq mm cable.