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Issue No: Description Rev. Description

1 0 -
As per Comments from TKIIL
2 email dated 30/03/07
3 As per TKIIL comments email
dated 10/05/07

DESIGN CALCULATIONS FOR HT

POWER CABLES

Total Sheets Ten (Inclusive of the cover sheet)

Project Name 2x 25MW TPP AT ADITYA CEMENT, SHAMBHUPURA

TKII Proj Ref. 26294

Approved By SRS ABB- Drg / Doc No:

Checked By

Prepared By
VPN

NPS ABB 3BYN467456-SAE

Date of issue 13/06/2007

TKII Proj Doc. No. 2M0003-L-DOC-0104-0

Owner Aditya Cement Ltd.

Owner’s Consultant Fichtner Consulting Engineers (I) Pvt. Ltd.

Customer Thyssenkrupp Industries India Pvt Ltd.

Customer’s Consultant Avant-Garde Engineers and Consultant (P) Ltd

 We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © ABB

CONTENTS:

1 OBJECTIVE:....................................................................................................................... 3
2 TECHNICAL SPECIFICATIONS:.................................................................................... 3
3 REFERENCES: .................................................................................................................... 3
4 DESIGN CRITERIA:........................................................................................................... 3
5 DESIGN BASIS: ................................................................................................................... 3
6 CALCULATIONS:............................................................................................................... 4
7 RECORD OF REVISION.................................................................................................. 10

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SPECIFICATION & DESIGN CRITERIA FOR SELECTION OF HT POWER

CABLES.

A) HT POWER CABLES :

1 OBJECTIVE:
To size 11kV (UE), 6.6kV (UE), XLPE insulated, Armoured, Aluminum, Power cables.

2 TECHNICAL SPECIFICATIONS:
11kV, 6.6kV cables shall be heavy duty XLPE insulated with stranded aluminum. Each core screened
on conductor as well as insulation, colour coded, extruded PVC inner sheathed, Galvanized steel strips
armored for multicore cables with aluminium or non magnetic armour for single core cables and
extruded FRLS PVC outer sheathed. The cables will be suitable for unearthed system.

3 REFERENCES:
Current ratings taken from catalogue of RPG CABLES for 11 kV 6.6kV, XLPE insulated, armoured,
Aluminum Power cables.

4 DESIGN CRITERIA:
The cross-section of cable selected shall fulfill the following criteria:
a) To be able to withstand the short-time fault current in the circuit for the duration of its circuit
interrupting device.
b) To be able to carry the full load current after considering appropriate derating factor for ambient
temperature variation, method of laying (in duct banks / trays in air/ concrete trenches).
c) Voltage drop limited to 2.5% and starting voltage drop to 15%.
d) Ambient temperature of 50o C is considered inline with contract.

5 DESIGN BASIS:
a) The maximum symmetrical fault level at 11 kV bus is as follows:
Max. Fault kA = 44 kA
b) Derating factor for continuous current rating = 0.7
c) Duration for Source/ Incomer/ Tie Feeders = 1.0 sec (As per DBR)
d) Duration for Outgoing Motor / Transformer Feeder = 0.16 sec (As per DBR)

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6 CALCULATIONS:
Based on the above design criteria and design basis, the calculations are carried out for Incoming /
Outgoing cables.

6.1 2 No of Feeder Cables to LC-2 from 11 kV Panel (total approximate distance each 950 m)
a) Short-time current withstand capability point of view:
Incoming Cable to LC-2 is sized to withstand 44 kA for 1.0sec.
i. Duration of short-circuit to be considered = 1.0 sec.
ii. Min.cross section required for 11kV(UE)
Cable to withstand 44 kA for 1.0 sec. = Ik √ t
k
Where K (constant) for Al. XLPE Cable = 0.094
= 44 x √ 1
0.094
= 468.08 sq.mm
Therefore, minimum cross section of the cable is selected as 1C x 630 sq.mm /XLPE (Al.) per
phase, that can withstand 44 kA for 1 sec.
b) Rated current carrying (continuously) capability:
i. Full load current at 11kV = 3280.5 A
ii. Current carrying capacity of 1Cx630sq.mm
Al. cable in air = 903 A
iii. Derated current carrying capacity of
1Cx630sq.mm cable 903 x 0.7 = 632.1 A
iv. No. of runs required = 3280.5 = 5.18 run = 6 run per phase
632.1
Therefore, the cable size selected as 6R#1C x 630 sq.mm /XLPE (Al.) per phase is adequate
from continuous current carrying point of view.

c) Steady state voltage drop for the cable connecting the 11kV Panel & LC-2:
i. Cable size (selected from above calculation) = 1Cx630sq.mm (Al.)
ii. Cable length (estimated max.) (L) = 950 m
iii. No. Of runs (n) = 6 per phase
iv. Cable resistance /Km (R) per run = 0.063 ohm/km
v. Cable reactance /Km (X) per run = 0.0973 ohm/km
vi. Cos Φ = 0.86 (assumed)
vii. Sin Φ = √1-cos2Φ = 0.510
viii. Max. full load current (I) = 3280.5 A

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ix Voltage drop ∆V = {√3x I x L x (RcosΦ + XsinΦ)}/n

= {√3x 3280.5x0.95(0.063x0.86+0.097x0.51)}/6
= 93.24 V

x. Percentage voltage drop = (∆V/V) X100%

= (93.24/11000) X 100%
= 0.84%
Thus it is seen, the % voltage drop in each phase is within the limitation of 2.5% and hence the selected cable
size 6R#1Cx630sq.mm / XLPE (Al.) per phase is adequate.

6.2 Outgoing cable to Existing 6.6kV from TPP Switchgear (total distance approximately 200 m)
a) Short-time current withstand capability point of view:
Incoming Cable to LC-2 is sized to withstand 44 kA for 1.0sec.

i. Duration of short-circuit to be considered = 1.0 sec.

ii. Min.cross section required for 6.6kV(UE)
Cable to withstand 44kA for 1 sec. = Ik √ t
k
Where K (constant) for Al. XLPE Cable = 0.094
= 44 x √ 1
0.094
= 468.08 sq.mm
Therefore, minimum cross section of the cable is selected as 1C x 630 sq.mm/ XLPE (Al.) per
phase that can withstand 44kA for 1 sec.
b) Rated current carrying (continuously) capability:
i. Full load current = 2799.36 A
ii. Current carrying capacity of 1C x 630 sq.mm
Al. cable in air = 902 A
iii. Derated current carrying capacity of
1Cx630 sq.mm cable 902 x 0.7 = 631 A
iii. No. of runs required = 2799.36 = 4.43 = 5 Runs per phase
631
Therefore, the cable size selected as 5R#1C x 630 sq.mm/ XLPE (Al.) per phase is adequate
from continuous current carrying point of view.
c) Steady state voltage drop for the cable connecting the Existing 6.6kV Switchgear & 6.6kV
Panel
i. Cable size (selected from above calculation) = 1C x 630 sq.mm (Al.)

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ii. Cable length (estimated max.) (L) = 200 m

iii. No. of runs (n) = 5 per phase
iv. Cable resistance /Km (R) per run = 0.063 ohm/km
v. Cable reactance /Km (X) per run = 0.093 ohm/km
vi. Cos Φ = 0.86 (assumed)
vii. Sin Φ = √1-cos2Φ = 0.510
viii. Max. Full load current (I) = 2799.36 A
ix Voltage drop ∆V = {√3x I x L x (RcosΦ + XsinΦ)}/n
= {√3x 2799.36x0.2(0.063x0.86+0.093x0.51)}/5
= 19.22 V
x. Percentage voltage drop = (∆V/V) X100%
= (19.22/6600) X 100%
= 0.29%

Thus it is seen, the % voltage drop in each phase is within the limitation of 2.5% and hence the
selected cable size 5R# 1C x 630/ XLPE (AL) per phase is adequate.

6.3 Outgoing cable to LC-1 from 6.6kV TPP Switchgear (total distance approximately 1300 m)

a) Short-time current withstand capability point of view:

Incoming Cable to LC-2 is sized to withstand 44 kA for 1.0sec.

i. Duration of short-circuit to be considered = 1.0 sec.

ii Min.cross section required for 6.6kV(UE)
Cable to withstand 44kA for 1 sec. = Ik √ t
k
Where K (constant) for Al. XLPE Cable = 0.094
= 44 x √ 1
0.094
= 468.08 sq.mm
Therefore, minimum cross section of the cable is selected as 1C x 630 sq.mm/ XLPE (Al.) per
phase that can withstand 44kA for 1 sec.
b) Rated current carrying (continuously) capability:
i. Full load current = 2799.36 A
ii. Current carrying capacity of 1C x 630 sq.mm
Al. cable in air = 902 A
iii. Derated current carrying capacity of
1Cx630 sq.mm cable 902 x 0.7 = 631 A
iv. No. Of runs required = 2799.36 = 4.43 = 5 Runs per phase
631

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Therefore, the cable size selected as 5R#1C x 630-sq.mm/ XLPE (Al.) per phase is adequate
from continuous current carrying point of view.
c) Steady state voltage drop for the cable connecting the 6.6kV Switchgear & LC-1
i. Cable size (selected from above calculation) = 1C x 630 sq.mm (Al.)
ii. Cable length (estimated max.) (L) = 1300 m
iii. No. of runs (n) = 5 per phase
iv. Cable resistance /Km (R) per run = 0.063 ohm/km
v. Cable reactance /Km (X) per run = 0.093 ohm/km
vi. Cos Φ = 0.86 (assumed)
vii. Sin Φ = √1-cos2Φ = 0.510
viii. Max. Full load current (I) = 2799.36 A
ix Voltage drop ∆V = {√3x I x L x (RcosΦ + XsinΦ)}/n
= {√3x 2799.36x1.3(0.063x0.86+0.093x0.51)}/5
= 125 V

x. Percentage voltage drop = (∆V/V) X100%

= (125/6600) X 100%
= 1.89%

Thus it is seen, the % voltage drop in each phase is within the limitation of 2.5% and hence the
selected cable size 5R# 1C x 630 /XLPE (Al) per phase is adequate.

6.4 Outgoing cable to 750kW BFP motor from 11kV TPP Switchgear distance approximately 250 m

a) Short-time current withstand capability point of view:

Incoming Cable to 750kW is sized to withstand 44 kA for 0.16sec.

i. Duration of short-circuit to be considered = 0.16 sec.

ii Min.cross section required for 6.6kV(UE)
Cable to withstand 44kA for 0.16 sec. = Ik √ t
k
Where K (constant) for Al. XLPE Cable = 0.094
= 44 x √ 0.16
0.094
= 187.23sq.mm
Therefore, minimum cross section of the cable is selected as 3C x 240 sq.mm / XLPE (Al.) that
can withstand 44kA for 0.16 sec.

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b) Rated current carrying (continuously) capability:

i. Full load current approximately = 48 A
ii. Current carrying capacity of 3C x 240 sq.mm
Al. cable in air = 429 A
iii. Derated current carrying capacity of
3Cx240 sq.mm cable 429 x 0.7 = 300.3 A
iv No. Of runs required = 48.0 = 0.16 = 1 Run
300.3
Therefore, the cable size selected as 1R#3C x 240 sq.mm /XLPE (Al.) is adequate from
continuous current carrying point of view.

c) Steady state voltage drop for the cable connecting the 11kV Switchgear & 750kW BFP
i. Cable size (selected from above calculation) = 3C x 240 sq.mm (Al.)
ii. Cable length (estimated max.) (L) = 250 m
iii. No. of runs (n) = 1
iv. Cable resistance /Km (R) per run = 0.161 ohm/km
v. Cable reactance /Km (X) per run = 0.098 ohm/km
vi. Cos Φ = 0.86 (assumed)
vii. Sin Φ = √1-cos2Φ = 0.510
viii. Max. Full load current (I) = 48 A
ix Voltage drop ∆V = {√3x I x L x (RcosΦ + XsinΦ)}/n
= {√3x 48x0.25(0.161x0.86+0.098x0.51)}/1
= 3.91 V during continuous run

x. Percentage voltage drop = (∆V/V) X100%

= (3.91/11000) X 100%
= 0.035% during continuous run

xi Voltage drop ∆V = {√3x 6I x L x (RcosΦ + XsinΦ)}/n

= {√3x288x0.25(0.161x0.86+0.098x0.51)}/1
= 23.5 V during starting

xii Percentage voltage drop = (∆V/V) X100%

= (23.5/11000) X 100%
= 0.21% during starting

Thus it is seen, the % voltage drop in each phase is within the limitation of 2.5% and starting
voltage drop is within 10% and hence the selected cable size 1R# 3C x 240 sq.mm/ XLPE (Al.)
is adequate.

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6.5 Outgoing cable to 3.15 MVA Transformer from 11kV TPP Switchgear distance approximately
100 m

a) Short-time current withstand capability point of view:

Incoming Cable to 3.15 MVA Transformer is sized to withstand 44 kA for 0.16sec.

i. Duration of short-circuit to be considered = 0.16 sec.

ii Min.cross section required for 6.6kV(UE)
Cable to withstand 44kA for 0.16 sec. = Ik √ t
k
Where K (constant) for Al. XLPE Cable = 0.094
= 44 x √ 0.16
0.094
= 187.23sq.mm
Therefore, minimum cross section of the cable is selected as 3C x 240 sq.mm /XLPE (Al.) that
can withstand 44kA for 0.16 sec.
b) Rated current carrying (continuously) capability:
i. Full load current = 165.33 A
ii. Current carrying capacity of 3C x 240 sq.mm
Al. cable in air = 429 A
iii. Derated current carrying capacity of
3Cx240 sq.mm cable 429 x 0.7 = 300.3 A
iv No. Of runs required = 165.33 = 0.55 = 1 Run
300.3
Therefore, the cable size selected as 1R#3C x 240 sq.mm/ XLPE (Al.) is adequate from
continuous current carrying point of view.

c) Steady state voltage drop for the cable connecting the 11kV Switchgear & 3.15MVA
Transformer
i. Cable size (selected from above calculation) = 3C x 240 sq.mm (Al.)
ii. Cable length (estimated max.) (L) = 100 m
iii. No. of runs (n) = 1
iv. Cable resistance /Km (R) per run = 0.161 ohm/km
v. Cable reactance /Km (X) per run = 0.098 ohm/km
vi. Cos Φ = 0.86 (assumed)
vii. Sin Φ = √1-cos2Φ = 0.510
viii. Max. Full load current (I) = 165.33 A
ix Voltage drop ∆V = {√3x I x L x (RcosΦ + XsinΦ)}/n
= {√3x 165.33x0.1(0.161x0.86+0.098x0.51)}/1
= 5.40 V

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x. Percentage voltage drop = (∆V/V) X100%

= (5.40/11000) X 100%
= 0.049%

Thus it is seen, the % voltage drop in each phase is within the limitation of 2.5 and hence the selected
cable size 1R# 3C x 240 sq.mm / XLPE (Al) is adequate.

The Short Circuit Current calculations hold good for 2.5MVA and 2MVA Transformer as well and
hence the calculated cable size of 3C X 240 sq.mm is also adequate for the same.

c
B

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