28th July 2012

The Executive Director

Th: Jt. V.P. (R&D)
Sub: Cable Selection guidelines, Quality Testing
Sir,
Following are the Cable selection guidelines followed for proper and efficient selection of
cables:
I.

ELECTRICAL CABLE SELECTION

Selecting a cable for primary and secondary power circuits, following points are considered:
1. Type of installation:
The cable in underground applications, outdoor applications, or indoor applications. In each
of
these
applications
the
requirement
of
cables
are
different.
Outdoor applications: The cables selected should be suitable for wet installation conditions.
Indoor applications: The interlocked armor cable is a useful option and it rectifies the
requirement of a conduit and it is totally a self contained unit. Besides its specific
advantages it need 20 to 50% less cost requirement than the traditional conduit system.
2. Voltage requirement
The voltage determination for the electrical device is needed to buy the proper cable. The
type and thickness of insulation is determined by the voltage factor. It also helps in
determining the minimum size of conductor that is suitable for small loads. Besides that it is
also important to know that whether grounded or ungrounded neutral is used.
3. Ampacity requirements
Determining the final conductor size require the ampacity of KVA loading. The power
factor, current load, and KVA load should be known prior to finalize the size of conductor.
Sometimes the cable size is determined by voltage drop rather than only by heating. In any
uncertain situations the size is determined separately by voltage drop and by heating, and
then the bigger size must be chosen.
4. Heating conditions
Heating conditions include the external thermal conditions which are responsible for
determining the temperature increment of a cable. Some important factors which affect the
selection of cables:
a. Ambient Temperature
b. Presence of Artificial Cooling
c. Number of Cables in a Duct Bank
d. Proximity to other Cables
e. Thermal Conductivity of Soil or other Surrounding Medium

f. Depth of Buried Cable

g. Nature of Surrounding Atmosphere (Heating area ie: -Dusty environment, cables nearby
boiler, steam lines etc)
5. Care should be taken to opt for the cable specifications with lesser ohm/km values for a
specific cable from a specific supplier.
6. Cable routing should be done so as to avoid extra lengths which can add to the power losses.
Also care should be taken to avoid sharp bends in cables at risers, duct bends etc in cable
laying procedure. Permissible bending radius of XLPE cables is as follow:Non Armoured

Armoured

Single Core

10D

15D

Multi Core Cable

8D

10D

A cable should be pulled with a pulling eye or pulling grip. The maximum
pulling tension must not be more than 500 Kg
7. Cost benefit analysis in terms of payback to be carried out to go for extra cable runs, Cable
Size and the losses which can be avoided. Detailed calculations can be done for each of the
suppliers specifications to correctly arrive at the best cable make.
8. Based upon the past experience from the Electrical persons, selection should be made
between Al or Cu conductors with careful analysis to compare the running cost with the
initial cost.
9. If the voltage rating is above 5000V, check whether cable is shielded or not. In case of
voltage rating like 8000V, 15000V, 25000V or 30000V, will the cable be provided grounded
neutral or ungrounded neutral.
10. There are various materials used for insulation of wires and cables and some are specific to
particular types of uses. So the type of insulation must be known before purchasing.
11. The reference ambient temperature to be considered is 50C.
12. Minimum size of LV power cables shall be selected considering following factors:
a) Feeder short circuit current and duration for ACB (air circuit breaker) controlled feeders
and motors
b) Feeder continuous current
c) Cable installation conditions
d) Voltage drop under normal running and starting of motors
13. For ACB operated feeders following sizing calculation for deriving minimum conductor size
shall follow,
14. A = Ift /k
where,

A = conductor area in mm
If = fault current in kA
t = duration of fault in second
K = a constant depending upon the type of insulation/ conductor material, heat capacity
of conductor material, resistivity, temp-coefficient, initial-final temp
K = 115 for Copper Conductor with PVC insulation
K = 143 for Copper Conductor with insulation XLPE or EPR
K = 76 for Aluminum Conductor with PVC insulation
K = 94 for Aluminum Conductor with insulation XLPE
Duration of fault (t) for various types of feeder shall be considered as below:
Power supply feeders 0.16 seconds
Motor feeders 0.1 seconds (Assuming contactor Feeder in HT/LT motors and all are
having fuse protection as a backup short circuit protection and consider fuse blown and
isolation time is 0.10 Sec)
For Cable Size calculation consider maximum bus fault level 40 K
Amps for HT system because bus fault level will be increased in
further addition of load on the bus, accordingly cable size will be
changed, so consider cable size according to max bus fault level
15. Maximum allowable voltage drop in percentage of the nominal system voltage in cables
shall be as below:
a)
For power supply feeders - 3%
b)
At motor terminals during running - 3%
c)
At motor terminals during starting - 15%
Due to unavailability of motor datasheets, following motor parameters can be considered
on conservative side:
i. LV motor efficiency - 90%
ii. Motor starting power factor - 0.2
iii. Motor running power factor
iv. For motors < 37kW - 0.8
v. For motors 37kW - 0.85
vi. Motor starting current - 6 times the FLA (subject to IS tolerance, i.e. 20%)
16. Apart from above, consideration shall also be given to limit the cables to some standard
sizes, instead of using too many sizes.
17. Bypass DOL operation is considered for cable sizing of VFD controlled motors
The cable selection from VFD panel to motor is important due to RFI generated.
Shielded /XLPE power cable is generally recommended by the VFD manufacturers. The
power cable shall be laid by separate cable tray.

For VFD driven motors, consider separate earthing from VFD to motor, so consider
3.5 core cables for motor to VFD (1/2 Core is used for motor earthing) or a separate
single core Cable from VFD to motor for motor earthing.
18. Considering cable installation, following correction (derating) factors are considered:
a) For 1C (single core) cables laid in above grade trays (cable manufacturer data):
a. Ambient air temperature (50C) correction factor = K1 = 0.9
b. Group rating factor = K2 = 0.92 (for 1C LV cables laid in trays exposed to air, cables
in trefoil formation, separated by two cable diameter horizontally, three trefoils per
tray and the trays are in tiers having 300mm distance)
b) For 3C (three core) cables laid in above grade trays (cable manufacturer data):
a. Ambient air temperature (50C) correction factor = K1 = 0.9
b. Group rating factor = K2 = 0.68 (for 3C LV cables laid in trays exposed to air, the
cables touching, six cables per tray, total 6 trays and the trays are in tiers having
300mm distance, the clearance between wall and the cable is 25mm)
c) For 3C (three core) cables laid in ground:
a. Ambient air temperature (50C) correction factor = K1 = 0.9
b. Group rating factor/ Cable laying arrangement = K2
c. K3 = Depth of laying for cables lay direct in ground.
d. K4 = Variation in thermal resistivity of soil.
So, K = K1 * K2 * K3 * K4
(K3 and K4 is applicable only for underground cable not for
cable in air/ Over head cable)
CASE STUDY: CABLE SELECTION FOR 30 KW MOTOR
A. Case Study-1:Full Load Current = 54 Amp.
Condition of laying: Cable shall be laid in Air on cable gallery with 6 tier
and max. 9 cables in a tray. Ambient temp shall be 45 C
Derating Factor for 45 C is 0.95
Derating Factor for 6 nos. cable tier and 6 nos. of Cables per tray is 0.68
Total Derating factor = 0.68*0.95=0.648
Effective current rating of cable must be = 54/0.648 = 83.33 amp.
Nearest Cable size of above rating available = 3C * 25 sq.mm which have current carrying
capacity of 90 Amp.
Let the length of cable requirement is 200m .The voltage drop calculated work out is 5.4 %.
Voltage drop below 5 % is considered as safe limit and if higher voltage drop is there then there
is possibility of cable heating , as well higher starting current due to lower voltage available at

motor terminal . Hence we should consider one size higher i.e.3C*35 sq.mm for larger distance
of cable requirement if drive is at remote location.
From above Case Study
Motor current 54 Amps
For 54 Amps Continuous current flow and cable length > 200 meter, 35mm2 Aluminum Cable
will be heated at the termination end (Motor/Feeder end) and also I2R looses are high .
In my opinion Aluminum cables below 400mm2 consider as below
Continuous Current flow should be almost equal to Cross section of the cable
Cable Loss Calculation for LT PVC Cables at 70C (I2R Loss comparison between 25/35 and 50
mm2 aluminum cables)
Description

UOM

Cable Size

mm2

25

35

50

Current Capacity in Air

Amps

90

105

135

0.68

0.68

0.68

Derating Factor

Aluminium Cables Selection

Actual Current capacity after derating Factor

Amps

61.2

71.4

91.2

Current Flow

Amps

54

54

54

Ohm/KM

1.44

1.04

0.770

Cable Length

KM

0.2

0.2

0.2

Cable Copper Loss

KW

2.52

1.82

1.35

Cable Losses/Year RH 330 Days

KWH/Year

19954

14411

10670

Loss in Rs/Year @ 3.5/KWH

Lac Rs/Year

0.70

0.50

0.37

Rs/ Meter

75

90

113

Rs

15000

18000

22600

Year

0.23

0.35

Cable DC Resistance at 70C

Cable Rate
Amount

Pay Back Period If 50 mm2 Cable will be

considered

So, 25 mm2 even though capable to take the current but if we consider the I 2R Cable losses, then
we must go with 50mm2 cable for long run. So, for selecting cable size, cable losses with
payback period always kept in mind.
B. Case Study-2:-

Cable Loss Calculation (I2R Loss comparison between 120, 150 & 185 and 240, 300 and 400
mm2 aluminum cables)
Description

UOM

A. Aluminum Cables
Selection

C. Aluminum Cables
Selection

Cable Size

mm2

120

150

185

240

300

400

Current Capacity in Air

Amps

240

275

315

380

430

490

0.68

0.68

0.68

0.68

0.68

0.68

Derating Factor
Actual Current capacity
after derating Factor

Amps

163

187

214

258

292

333

Current Flow

Amps

150

150

150

300

300

300

Ohm/KM

0.305

0.249

0.198

0.152

0.122

0.0961

Cable Length

KM

0.2

0.2

0.2

0.2

0.2

0.2

Cable Copper Loss

KW

4.1175

3.361
5

2.673

5.7

4.575

3.60

KWH/Year

32611

26623

21170

45144

36234

28542

Rs/Year

1.14

0.93

0.74

1.58

1.27

1.00

Rs/ Meter

226

240

300

450

594

792

Rs

0.452

0.48

0.60

0.90

1.188

1.58

Year

0.37

0.63

1.18

1.47

Cable DC Resistance at
70C

Cable Losses/Year RH
330 Days
Loss in Rs/Year @
3.5/KWH
Cable Rate
Amount in Lacs

Pay Back Period If we

consider higher size
cable
Conclusion

So, in cable selection, also have to be check techno-economical selection between Cable
copper losses and Cable cost and place suitable cable considering limitations of termination
space in panel and Motor terminal box for termination.
For motor termination, in place of one big size cable consider two lower rating cable (Ex in
place of 1Rx300 mm2 Cable, we can consider 2Rx150 mm2 Cable to avoid issues of cable
termination, cable bending at termination point, lug heatings etc)
II LATEST METHOD FOR SELECTING OPTIMUM CABLE
1. For faster and accurate cable sizing calculations Excel Spreadsheet is available which can be
used for cable sizing.

2. For further refined and optimum cable sizing advanced software packages such as e-TAP can be
used
Benefits of ETAP: e-TAP cable sizing study module calculates optimal and alternative cable
sizes for phase conductors which contains large cable selection library and calculates on the
following criteria:
Load current
Voltage drop
Motor minimum starting voltage
Short circuit current
Protective device requirements
Harmonic Spectrum
[As per initial discussions with the supplier, e-TAP software is available with the Shree
Cement, probably at Power Plant]
III QUALITY TESTING
For testing the quality of the Supplied cables certain tests AS PER IS:1554 (P-I) AND IS:7098
(P-I) are required which requires elaborative testing facility. Special tests can be carried out by
an agreement between the SCL and the manufacturer.
However, at own site quality testing the cable ohm/m values against the offered specifications
micro-ohm meter can be used. All new cables shall be Megger-tested before jointing.
Following are the types of Quality Tests conducted by Manufacturer or Accredited Laboratories:

1. Routine Tests:
a. Conductor Resistance Test
b. High Voltage Test and
c. Armour resistance test (for mining cables)
2. Type Tests:
a. Test on conductors (IS 8130:1984)
i. Tensile Test (for Aluminium Conductor)
ii. Wrapping Test (for Aluminium Conductor)
iii. Annealing Test (for Copper Conductor)
iv. Conductor Resistance Test
b. Test for Armour Wire / Strips (IS 1554, Part-1)
c. Test for thickness of Insulation & Sheath
d. Physical Test for Insulation & Outer Sheath (IS5831:1984)
e. Insulation Resistance Test (IS5831:1984)
f. High Voltage Test (Water Immersion test) and at Room Temperature
g. Flammability Test
h. Hot Set Test (for XLPE Insulation only)
i. Water Absorption Test (for XLPE cables)
3. Acceptance Tests:
a. Tensile Test (for Aluminum Conductor)
b. Wrapping Test (for Aluminum Conductor)
c. Annealing Test (for Copper Conductor)
d. Conductor Resistance Test

e. Test for thickness of Insulation & Sheath

f. High Voltages Test (IS 10810, part-45)
g. Insulation Resistance Test at Room temperature (IS 10810, part-43)
h. Tensile Strength & Elongation at break test for Insulation & Sheath
4. Optional Tests :
a. Cold Bend Test
b. Cold Impact Test
c. Armour resistance test (for other than mining cables)
5. Special Tests:
a. Oxygen Index Test as per ASTMD 2863 77
b. Temp. Index Test as per ASTMD 2863 77
c. Smoke Generation Test as per ASTMD 2843 77
d. Acid Gas Generation Test as per IEC 754 1
e. Flammability Test as per IEC 332 1, IEEE 383, SS 4241475 Class F3 and IE 332
1
f. Accelerated water absorption test (by Electrical Method)
g. Test for Anti-rodent & Anti-termite property
h. Color fastness to water & air

Regards
Central Energy Cell