HT Cable Sizing

By
KPP Date 20/11/2006 Chd. DRS Date 20/11/2006
Project Client TPL
1 x 80 MW CPP - HZL
6.6kV CABLE SIZING TRANSFORMER FEEDERS ON U3
TCE.4894A-EL-CAL-713-01 Doc. No. TCE.4894A-715-EL-CAL-01

Subject
Job No.-TCE.
Office 4894A
Dept. DB
EL
Rev. No.
R0
1.0 1.1
INPUT DATA Fault current (Ish) Maximum fault current of the system = 26.2 kA for 1 Second
1.2
Fault clearing time (t) for outgoing feeders = 0.16 Second (wherever high set instantaneous protection is provided) Fault clearing time (t) for incomer feeders Fault clearing time (t) for tie feeders = = = 1 Second
0.5 Second 94
1.3 1.4
Constant (K) for Aluminium conductor
Derating factors, Resistance, Reactance values and current ratings from UNISTAR Cable Catalogue Derating factor for Single Core cables (i) Derating factor for variation in temperature - 0.94 (ii) Derating factor for laying - 0.9 (with spacing twice the cable diameter) Overall derating factor = 0.94*0.9 = 0.846 Derating factor for Three Core cables (i) Derating factor for variation in temperature - 0.94 (ii) Derating factor for laying - 0.66 Overall derating factor = 0.94*0.66 = 0.62 6.6 kV cables are of unearthed type
1.5
1.6
1.7
2.0
Formula used to calculate the cable size on short circuit rating For Incomer feeders : A = ( Ish in Amps x t ) / K
Minimum size of the cable

For Outgoing feeders : A = ( Ish in Amps x t ) / K
= 278.7 sq.mm (for 1.0 sec)

For tie feeders : A = ( Ish in Amps x t ) / K
= 111.5 sq.mm (for 0.16sec)
Minimum size of the cable 3.0 A) INCOMER FROM UAT 3A OVERALL DERATING FACTOR
Transformer rating Rated Voltage of TRF. Rated current of TRF. After derating = Number of runs / phase Number of runs / phase = 669.19
= 197.1 sq.mm (for 0.5sec)
=
= = = 12.5 6.6 MVA kV
0.846
1093.47 Amps 791 Amps in air
Current carrying capacity of 1Cx630 sqmm cable = Amps = 2.0 1.63
( Rounded off to nearest integer value)
Selected cable size = 4X1CX630 2 X1CX630 sq.mm per phase sq.mm per phase TOTAL CABLE CAPACITY = 1338.4 AMPS
PAGE 1 OF 12
TCE FORM NO. 010R0
By
Project Client TPL
1 x 80 MW CPP - HZL
6.6kV CABLE SIZING TRANSFORMER FEEDERS ON U3

Subject
Job No.-TCE.
Office 4894A
Dept. DB
EL
Rev. No.
R0
B) OUTGOING TO ESPT OVERALL DERATING FACTOR

Transformer rating Rated Voltage of TRF. Rated current of TRF. After derating = Number of runs / phase Number of runs / phase = 162.44 = = = 1.6 6.6 139.96
=
MVA kV Amps
0.62
Current carrying capacity of 3Cx120sqmm cable = Amps = 1.0 0.86
262
Amps
in air
Selected cable size = 4X1CX630 1 X3CX120 sq.mm per phase sq.mm TOTAL CABLE CAPACITY = 162.4 AMPS
C) OUTGOING TO UST/COOLING TRANSFORMER OVERALL DERATING FACTOR

Running load rating Rated Voltage of TRF. Rated current of TRF. After derating = Number of runs / phase Number of runs / phase = 162.44 = = = Amps = 1.0 0.54 ( Rounded off to nearest integer value) 1 6.6 87.48
=
MVA kV Amps
0.62
Current carrying capacity of 3Cx120sqmm cable =
262
Amps
in air
PAGE 2 OF 12
TCE FORM NO. 010R0
By
Project Client TPL
1 x 80 MW CPP - HZL
6.6kV CABLE SIZING TRANSFORMER FEEDERS ON C3
Doc. No. TCE.4894A-715-EL-CAL-01 TCE.4894A-EL-CAL-713-01 Subject
Job No.-TCE.
Office 4894A
Dept. DB
EL
Rev. No.
R0
1.0 1.1
1.2
0.5 Second 94
1.3 1.4
1.5
1.6
1.7
2.0
OUTGOING FEEDERS
A) OUTGOING TO SST OVERALL DERATING FACTOR

Running load rating Rated Voltage of TRF. Rated current of TRF. After derating = Number of runs / phase Number of runs / phase = 210.80 = = = 2 6.6 174.95
=
MVA kV Amps
0.62
Current carrying capacity of 3Cx185sqmm cable = Amps = 1.0 0.83
340
Amps
in air
PAGE 3 OF 12
TCE FORM NO. 010R0
By
Project Client TPL
1 x 80MW CPP - HZL

6.6kV CABLE SIZING MOTOR FEEDERS ON U3

Subject
Job No.-TCE.
Office 4894A
Dept. DB
EL
Rev. No.
R0
1.0 1.1
INPUT DATA Fault current (Ish) Maximum fault current of the system = = = 26.2 kA for 1 Second 0.16 Second 94
1.2 1.3 1.4
Fault clearing time (t) Constant (K) for Aluminium Conductor
Derating factors, Resistance, Reactance values and current ratings from UNISTAR Cable Catalogue Derating factor for Single Core cables (i) Derating factor for variation in temperature - 0.94 (ii) Derating factor for laying - 0.9 (with spacing twice the cable diameter) Overall derating factor = 0.94*0.9 = 0.846 Derating factor for Three Core cables (i) Derating factor for variation in temperature - 0.94 (ii) Derating factor for laying - 0.66 Overall derating factor = 0.94*0.66 = 0.62 Efficiency and P.F. for HV motors as per BHEL datasheets
1.5
1.6
1.7
2.0 To calculate the cable size on short circuit rating A = ( Ish in Amps x t ) / K Minimum size of the cable = 111 sq.mm
3.0
BUS U3A
A) COAL MILL 1 OVERALL DERATING FACTOR Feeder rating = Rated Voltage of feeder = Efficiency Rated pf = = 0.21 MW 6.6 kV 0.92 0.71 0.62
Rated current of Motor = 28.12 Amps Current carrying capacity of 3Cx120 sqmm cable = 262 Amps in air 162.44 After derating = Amps 0.17 Number of runs / phase = Number of runs / phase = 1.0 ( Rounded off to nearest integer value) 1 x3Cx120 sq.mm Selected cable size = 162.4 Amps TOTAL CABLE CAPACITY =
B) BOILER FEED PUMP 1A OVERALL DERATING FACTOR Feeder rating Rated Voltage of feeder Efficiency Rated pf = 2.13 MW 6.6 kV 0.97 0.88 0.62
= = = =
TCE FORM NO. 010R0
By
Project Client TPL
1 x 80MW CPP - HZL


Subject
Job No.-TCE.
Office 4894A
Dept. DB
EL
Rev. No.
R0
Rated current of Motor = 219.41 Amps Current carrying capacity of 3Cx240sqmm cable = 400 Amps in air After derating = Amps 248.00 Number of runs / phase = 0.88 Number of runs / phase = 1.0 ( Rounded off to nearest integer value) Selected cable size = 1 x3Cx240 sq.mm 248.0 Amps TOTAL CABLE CAPACITY =
C) CONDENSATE EXTRACTION PUMP 1A OVERALL DERATING FACTOR Feeder rating Rated Voltage of feeder Efficiency Rated pf = 0.25 MW kV 6.6 0.94 0.85 0.62
= = = =
Rated current of Motor = 27.52 Amps Current carrying capacity of 3Cx120 sqmm cable = 262 Amps in air After derating = 162.44 Amps Number of runs / phase = 0.17 Number of runs / phase = 1.0 ( Rounded off to nearest integer value) Selected cable size = 1 x3Cx120 sq.mm 162.4 Amps TOTAL CABLE CAPACITY =
D) P.A. FAN 1A OVERALL DERATING FACTOR Feeder rating = Rated Voltage of feeder = = 0.5 MW 6.6 kV 0.62
Efficiency = 0.94 Rated P.F. = 0.85 Rated current of Motor = 54.74 Amps 262 Amps in air Current carrying capacity of 3Cx120 sqmm cable = After derating = 162.44 Amps Number of runs / phase = 0.34 Number of runs / phase = 1.0 ( Rounded off to nearest integer value) Selected cable size = 1 x3Cx120 sq.mm 162.4 Amps TOTAL CABLE CAPACITY =
E) F.D. FAN 1A OVERALL DERATING FACTOR Feeder rating = Rated Voltage of feeder = Efficiency Rated pf = = 0.275 MW 6.6 kV 0.95 0.79 0.62
Rated current of Motor = 32.12 Amps Current carrying capacity of 3Cx120 sqmm cable = 262 Amps in air After derating = Amps 162.44 Number of runs / phase = 0.20 Number of runs / phase = 1.0 ( Rounded off to nearest integer value) Selected cable size = 1 x3Cx120 sq.mm 162.4 Amps TOTAL CABLE CAPACITY =
TCE FORM NO. 010R0
By
Project Client TPL
1 x 80MW CPP - HZL


Subject
Job No.-TCE.
Office 4894A
Dept. DB
EL
Rev. No.
R0
F) I.D. FAN 1A OVERALL DERATING FACTOR Feeder rating = Rated Voltage of feeder = Efficiency Rated pf = = 0.5 MW 6.6 kV 0.95 0.79 0.62
Rated current of Motor = 58.40 Amps 262 Amps in air Current carrying capacity of 3Cx120sqmm cable = 162.44 After derating = Amps 0.36 Number of runs / phase = Number of runs / phase = 1.0 ( Rounded off to nearest integer value) Selected cable size = 1 x3Cx120 sq.mm 162.4 Amps TOTAL CABLE CAPACITY = G) COOLING WATER PUMP 3A OVERALL DERATING FACTOR Feeder rating = Rated Voltage of feeder = Efficiency Rated P.F. = = 0.52 MW 6.6 kV 0.95 0.9 0.62
Rated current of Motor = 53.20 Amps 262 Amps in air Current carrying capacity of 3Cx120 sqmm cable = 162.44 After derating = Amps 0.33 Number of runs / phase = Number of runs / phase = 1.0 ( Rounded off to nearest integer value) Selected cable size = 1 x3Cx120 sq.mm 162.4 Amps TOTAL CABLE CAPACITY =
TCE FORM NO. 010R0
By
Project Client TPL
1 x 80 MW CPP - HZL
6.6kV CABLE SIZING FEEDERS TIE
Job No.-TCE.
Office 4894A
Dept. DB
EL
Rev. No.
R0
1.0 1.1
1.2
0.5 Second 94
1.3 1.4
1.5
1.6
1.7
2.0

For Outgoing feeders : A = ( Ish in Amps x t ) / K
= 335.1 sq.mm (for 1.0 sec)

For tie feeders : A = ( Ish in Amps x t ) / K
134
sq.mm (for 0.16sec)
237
sq.mm (for 0.5sec)
A) INCOMER TO STATION BUS C3A/C3B OVERALL DERATING FACTOR

Station bus rating Rated Voltage Rated current. = = = 6.6
=
2000 A kV 1250.00 Amps
0.846
With 20% of margin total current for the bus comes to 1250A only. Current carrying capacity of 1Cx630 sqmm cable = After derating = Number of runs / phase Number of runs / phase = 669.19 Amps = 2.0 1.87 ( Rounded off to nearest integer value) 791 Amps in air
PAGE 7 OF 12
TCE FORM NO. 010R0
By
Project Client TPL
1 x 80 MW CPP - HZL
6.6kV CABLE SIZING FEEDERS TIE
Job No.-TCE.
Office 4894A
Dept. DB
EL
Rev. No.
R0
B) TIE FEEDER - STATION BUS TO UNIT BUS OVERALL DERATING FACTOR

Unit bus rating Rated Voltage Rated current. After derating = Number of runs / phase Number of runs / phase = 669.19 = = = 6.6
=
1000 A kV 1000.00 Amps
0.846
791
Amps
in air
PAGE 8 OF 12
TCE FORM NO. 010R0
By
Project Client TPL
1 x 80MW CPP - HZL

6.6kV CABLE SIZING MOTOR FEEDERS ON C3

Subject
Job No.-TCE.
Office 4894A
Dept. DB
EL
Sh.
OF
Rev. No.
R0
1.0 1.1
INPUT DATA Fault current (Ish) Maximum fault current of the system = = = 31.5 kA for 1 Second 0.16 Second 94
1.2 1.3 1.4
Fault clearing time (t) Constant (K) for Aluminium Conductor
Derating factors, Resistance, Reactance values and current ratings from UNISTAR Cable Catalogue Derating factor for Single Core cables (i) Derating factor for variation in temperature - 0.94 (ii) Derating factor for laying - 0.9 (with spacing twice the cable diameter) Overall derating factor = 0.94*0.9 = 0.846 Derating factor for Three Core cables (i) Derating factor for variation in temperature - 0.94 (ii) Derating factor for laying - 0.66 Overall derating factor = 0.94*0.66 = 0.62 Efficiency and P.F. for HV motors as per BHEL datasheets
1.5
1.6
1.7
2.0 To calculate the cable size on short circuit rating A = ( Ish in Amps x t ) / K Minimum size of the cable = 134 sq.mm
3.0
BUS C3
A) COMPRESSOR MOTOR OVERALL DERATING FACTOR Feeder rating = Rated Voltage of feeder = Efficiency Rated pf = = 0.22 MW 6.6 kV 0.92 0.71 0.62
Rated current of Motor = 29.46 Amps Based on the short circuit criteria cable size of 3CX150 sqmm cable is selected. 290 Amps in air Current carrying capacity of 3Cx150 sqmm cable = 179.80 After derating = Amps 0.16 Number of runs / phase = Number of runs / phase = 1.0 ( Rounded off to nearest integer value) Selected cable size = 1 x3Cx150 sq.mm 179.8 Amps TOTAL CABLE CAPACITY =
TCE FORM NO. 010R0
By Date Chd. Date
KPP BMJ 20/11/2006 DRS 20/11/2006
Project Client TPL
1x80MW CPP, phase-II

415V FEEDERS CABLE SIZING
Doc. No. TCE.4894A-715-EL-CAL-01 Subject
Job No.-TCE.4894A
Office
Dept. DB
EL
Rev. No.
R0
1.0 1.1
INPUT DATA Fault current (Ish) Maximum fault current of the system = = = 1 50 kA for 1 Second
1.2 1.3 1.4
Fault clearing time (t) Constant (K) for Aluminium conductor
Second 94
Derating factors, Resistance, Reactance values and current ratings from UNISTAR/KEI Cable Catalogue Derating factor for Single Core cables (i) Derating factor for variation in temperature - 0.95 (ii) Derating factor for laying - 0.79 (with spacing of twice cable dia) Overall derating factor = 0.95*0.79 = 0.7505 Derating factor for Three Core cables (i) Derating factor for variation in temperature - 0.95 (ii) Derating factor for laying - 0.66 Overall derating factor = 0.95*0.66 = 0.627
1.5
1.6
2.0

For tie feeders t= 0.5 secs Minimum size of the cable =376.12
= 531.9 sq.mm (for 1.0 sec)
3.0
Calculation A) UST/Cooling tower transformer OVERALL DERATING FACTOR

Transformer rating Rated Voltage of TRF. Rated current of TRF. After derating = Number of runs / phase Number of runs / phase = 610.50 = = = 1.0 0.433 1391.25
=
MVA kV AMPS
0.75
Current carrying capacity of 1Cx630 sqmm cable Amps = 3.0 2.27
814
Amps
in air
Selected cable size = 4X1CX630 3 X1CX630 sq.mm per phase sq.mm per phase Cable length between transformer and switchgear is less than15m & hence voltage drop is negligible B) ESPT / SST OVERALL DERATING FACTOR
Transformer rating Rated Voltage of TRF. Rated current of TRF. After derating = Number of runs / phase Number of runs / phase = 610.50 = = = 1.6 0.433
=
MVA kV
0.75
2225.99 Amps 814 Amps in air
Selected cable size
= 4X1CX630 4 X1CX630 sq.mm per phase sq.mm
PAGE 10 OF 12
TCE FORM NO. 010R0
By Date Chd. Date
KPP BMJ 20/11/2006 DRS 20/11/2006
Project Client TPL

Job No.-TCE.4894A
Office
Dept. DB
EL
Rev. No.
R0
C)
Cable from WST to water system swgr

Load KVA Rated Voltage of TRF. Rated current of TRF. Base Current Number of runs / phase Number of runs / phase = = = = = = 1.0 464 0.415 645.52 860.69 890 Amps in air 0.97 ( Rounded off to nearest integer value) KVA kV Amps
Current carrying capacity of 1Cx800 sqmm cable =
Selected cable size Cable length R= X= 0.053 ohms/km 0.075 ohms/km
= 4X1CX630 1 X1CX800 sq.mm per phase sq.mm per phase = approx. 50m
Voltage drop = I( R cos + X sin ) .l

Voltage drop = 645.52x ( 0.053 x 0.8 +0.075 x 0.6) x 0.05 Voltage drop = 2.8209V I.e 1.17% D) Tie to A/C ventilation switchgear from station service switchgear Full load current rating =736A Current carrying capacity of 1CX500sq mm Cable =693AMPS After derating = 519.75AMPS Number of runs / ph =1.416 Selected cable size =2x1Cx500 sqmm/ph Cable length length =100 0.076 x0.6 125 0.0808x0.8 voltage drop 736 x + x
415 3
1000 100 x
=2.11% E) Tie to Ash handling swgr from station service switchgear Full load current based on estimated load =392.90 AMPS Current carrying capacity of ICx500 sq mm Cable = 693A After derating =519.75 AMPS Cable Selected =1Cx500sqmm/ph Cable length =175m Voltage drop 175
3 93x = 1000
{0.0808x0.8
415 3
+ 0 . 076 x 0 . 6 } x 100
= 3.164%
PAGE 11 OF 12
TCE FORM NO. 010R0
By Date Chd. Date
KPP BMJ 20/11/2006 DRS 20/11/2006
Project Client TPL

Job No.-TCE.4894A
Office
Dept. DB
EL
Rev. No.
R0
F)
Tie to Normal/Emergency switchgear from USS Full load current =392.90AMPS current carrying capacity of ICx500sq mm cable =693A Therefore selecting 2x1Cx500sq mm/ph Cable length 100m
0.076x 0.6 100 0.0808x0.8 800 x + x 2 2 1000 x100 415 3
=1.84% G) Incomer to Normal/Emergency switchgear from DG full load current =800A current carrying capacity =693A After derating =519.75A No of run required =2 However inorder to limit the voltage (Refer DBR Annex-V) dip during AOP motor starting, cable slected =4x1Cx800sq mm/ph.
PAGE 12 OF 12
TCE FORM NO. 010R0

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KPP Date 20/11/2006 Chd. DRS Date 20/11/2006

Project Client TPL

TCE.4894A-EL-CAL-713-01 Doc. No. TCE.4894A-715-EL-CAL-01

Constant (K) for Aluminium conductor

Minimum size of the cable

= 278.7 sq.mm (for 1.0 sec)

Minimum size of the cable

= 111.5 sq.mm (for 0.16sec)

= 197.1 sq.mm (for 0.5sec)

1093.47 Amps 791 Amps in air

Current carrying capacity of 1Cx630 sqmm cable = Amps = 2.0 1.63

( Rounded off to nearest integer value)

TCE FORM NO. 010R0

KPP Date 20/11/2006 Chd. DRS Date 20/11/2006

Project Client TPL

TCE.4894A-EL-CAL-713-01 Doc. No. TCE.4894A-715-EL-CAL-01

B) OUTGOING TO ESPT OVERALL DERATING FACTOR

Current carrying capacity of 3Cx120sqmm cable = Amps = 1.0 0.86

( Rounded off to nearest integer value)

C) OUTGOING TO UST/COOLING TRANSFORMER OVERALL DERATING FACTOR

Current carrying capacity of 3Cx120sqmm cable =

TCE FORM NO. 010R0

KPP Date 20/11/2006 Chd. DRS Date 20/11/2006

Project Client TPL

Doc. No. TCE.4894A-715-EL-CAL-01 TCE.4894A-EL-CAL-713-01 Subject

Constant (K) for Aluminium conductor

A) OUTGOING TO SST OVERALL DERATING FACTOR

Current carrying capacity of 3Cx185sqmm cable = Amps = 1.0 0.83

( Rounded off to nearest integer value)

TCE FORM NO. 010R0

KPP Date 20/11/2006 Chd. DRS Date 20/11/2006

Project Client TPL

1 x 80MW CPP - HZL

TCE.4894A-EL-CAL-713-01 Doc. No. TCE.4894A-715-EL-CAL-01

1.2 1.3 1.4

Fault clearing time (t) Constant (K) for Aluminium Conductor

TCE FORM NO. 010R0

KPP Date 20/11/2006 Chd. DRS Date 20/11/2006

Project Client TPL

1 x 80MW CPP - HZL

TCE.4894A-EL-CAL-713-01 Doc. No. TCE.4894A-715-EL-CAL-01

TCE FORM NO. 010R0

KPP Date 20/11/2006 Chd. DRS Date 20/11/2006

Project Client TPL

1 x 80MW CPP - HZL

TCE.4894A-EL-CAL-713-01 Doc. No. TCE.4894A-715-EL-CAL-01

TCE FORM NO. 010R0

KPP Date 20/11/2006 Chd. DRS Date 20/11/2006

Project Client TPL

Doc. No. TCE.4894A-715-EL-CAL-01 TCE.4894A-EL-CAL-713-01 Subject

Constant (K) for Aluminium conductor

Minimum size of the cable

= 335.1 sq.mm (for 1.0 sec)

Minimum size of the cable

sq.mm (for 0.16sec)

Minimum size of the cable

sq.mm (for 0.5sec)