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Doc. Title:
MV & LV POWER CABLE Rev. No.: 2
SIZING STUDY

MV & LV POWER CABLE

SIZING STUDY

2 05.08.2013 Issued For Approval Electrical Dept. M.R. H.N. R.B.

1 10.06.2013 Issued For Approval Electrical Dept. M.R. H.N. R.B.

0 25.01.2013 Issued For Approval Electrical Dept. M.R. H.N. R.B.

Rev. Date Description Prepared Checked Approved Project

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MV & LV POWER CABLE Rev. No.: 2
SIZING STUDY

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MV & LV POWER CABLE Rev. No.: 2
SIZING STUDY

40
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Doc. Title:
MV & LV POWER CABLE Rev. No.: 2
SIZING STUDY

SECTION TITLE PAGE

1 INTRODUCTION 4

2 STANDARDS, CODES AND REGULATIONS 4

3 CABLE CONSTRUCTION 4

4 CABLE INSTALLATION 4

5 CABLE SIZING CRITERIA 5

6 CABLE SIZING PROCEDURE 5

7 PROJECT CABLE SIZING 7

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MV & LV POWER CABLE Rev. No.: 2
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1- INTRODUCTION

This document studies electrical cable cross section calculation and selection according to project
design criteria and cables specification. This study is applied for cables, which are under service
conditions noted in cable specification.

2- STANDARDS, CODES AND REGULATIONS

The cable sizing design shall comply with the applicable requirements of codes and standards
published by the following organizations:

International Electrotechnical Commission (IEC)

IEC 60287 electric cables- calculations of the current ratings
IEC 60502 cables for rated voltages of 600V up to and including 30 KV

3- CABLE CONSTRUCTION

According to cables specification, the cables construction is as follows:

-Conductor: copper stranded conductors
-Insulation material: XLPE (for MV cables), PVC (for LV cables)
-Shield: extruded semi-conducting shield+ plain annealed copper screen per core for MV type
-Innersheath: PVC
-Outersheath: PVC
-Maximum conductor temp.:90° c

4- CABLE INSTALLATION

In this project, cables in area will be installed on cable tray in the concrete cable trench and for
various voltage levels, separate cable trays will be installed and appropriate space is considered
between cable trays.
In other places such as substation and buildings of process area cables will be arranged on cable
trays of proper size.
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MV & LV POWER CABLE Rev. No.: 2
SIZING STUDY

5- CABLE SIZING CRITERIA

The cables will be sized with the following design criteria:

 Current rating
 Voltage drop
 Short circuit capacity

All 33 KV, low voltage distribution feeders, DC and UPS service cable will be individually sized.
Cable sizes will be rationalized in order to reduce the number of different cable types and sizes on the
project.

6- CABLE SIZING PROCEDURE

In this section sizing procedure for each criterion mentioned section 5 will be studied. Examples
are only for illustration of calculation method and current carrying capacities and impedance data that
are given in tables can be used in the absence of manufacturer's data.

6.1- CURRENT CARRYING- CAPACITY CALCULATION

1) Underground installation
current carrying-capacity shall be greater than the full load current divided by derating factor ”K”.
where:

K=Ka*Kd*Ks*Kg (Formula#1)

in which
K: overall derating factor
Ka: ambient temperature correction factor obtained from table 2.
Kd: depth of cable lay correction factor from table 3.
Ks: soil thermal resistivity correction factor obtained from tables 4-1 & 4-2. 1
Kg: grouping factor obtained from tables 5-1 & 5-2.

2) Aboveground installation
Current carrying capacity shall be greater than the full load current divided by derating factor “K”.
Where:
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MV & LV POWER CABLE Rev. No.: 2
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K=Ka*Kg (Formula#2)

In which
K: overall derating factor

Ka: ambient temperature correction factor obtained from table 2.

Kg: grouping factor obtained from tables 6, 7-1 & 7-2.

6.2- VOLTAGE DROP

Voltage drop will be calculated by following equations:

Direct current: (Formula#3)

For single-phase system: (Formula#4)

For 3-phase system: (Formula#5)

In which
= voltage drop percent
I = load current (A)
L = cable length (km)
U = line voltage
R = cable resistance (Ω/km)
X= cable reactance (Ω / km)
Cos : power factor

The electrical power system shall be designed to limit voltage drop (based on nominal voltage ) in
the feeder cables to the following values:

1) Feeders to transformers -1%

2) Feeders to switchboards -2%
3) Motor branch circuits -5% at full load up to 37 kW.
4) Motor branch circuits -3.5% at full load above 37 KW.
5) Lighting circuits -3%- panel board to last lighting fixture on circuit
-2%- power source to panel board
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MV & LV POWER CABLE Rev. No.: 2
SIZING STUDY

The maximum voltage drop in the motor feeder cable during motor starting shall be limited to 15% of
the nominal voltage.

6.3 short circuit capacity

Based on IEC 60724, the following formula will be used to calculate the minimum required cross
section of cores, to restrict temperature rise below 250 deg C for XLPE.

(Formula#6)

In which
S: minimum required cross section of cores.
ISC: short circuit current
TP: fault clearing time, equivalent to 0.25t+0.25 where “t” is relay operating time
K: constant depending on initial temperature, final temperature and material of conductor
insulation. This factor is 115 for PVC insulated copper wire and 143 for XLPE insulated copper
wire.
Where cables protected by fuse, the following formula can be used instead:

(Formula#7)

Where is let through energy of fuse, and shall be considered from fuse manufacturer's curves.

7- SAMPLE CALCULATION

7.1- Cable from MV Panel in Substation TO Transformer

a) current-carrying capacity
Voltage:33 kV
Maximum consumption load:1218 KW

=25.07 A

According to installation method as per section 4, correction factor for ambient temperature (from
table 2) and grouping factor (from Tables 6):
Ka = 0.73 (for 55C)
Kg = 0.98 ( Kg factor is extracted from table 6 and for these conditions:
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MV & LV POWER CABLE Rev. No.: 2
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Perforated trays, number of trays =1, number of three phase circuits =1)

And total derating factor is from equation (2):

K = Ka . Kg = 0.71
Thus for MV and LV cables and for total derating factor should be considered as 0.7
35.81

For this current the proper cable size will be: 3x(1x50mm2)

b) voltage drop
L=35 m=0.035 Km
The impedance of single core cable with 50 mm2 cross section area is 0.387+j0.156.

This voltage drop is acceptable.

c) short circuit capacity

The 33kV system has a maximum prospective short circuit capacity of 25 kA for 1 sec.
Assumed over current relay will operate to clear the short circuit fault within 0.5s, minimum cross
section of an XLPE cable, using Formula (6):

Tp=0.25+0.25t=0.25+0.25X0.5 (25 cycle=25/50=0.5)

mm2
Considering above items (a,b&c) the size of cable shall be 3x(1x120mm2) as minimum.
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7.2- Cable From Transformer to Main Low Voltage Distribution Board (SS-SWB-LV)

a) current-carrying capacity
Voltage:0.4 kV
Maximum consumption load:1218 KVA

=2068.27 A

Derating factor, K= 0.7

2954.67A

With consideration of 5 parallel cables route for each phases, single core cable with 400 mm2
cross section area is suitable.

b) voltage drop
L=25 m=0.025 Km
The impedance of single core cable with 50 mm2 cross section area is 0.0745+j0.079

This voltage drop is acceptable.

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MV & LV POWER CABLE Rev. No.: 2
SIZING STUDY

c) short circuit capacity

The 0.4kV system has a maximum prospective short circuit capacity of 40 kA for 1 sec.
Assumed over current relay will operate to clear the short circuit fault within 0.5s, minimum cross
section of an PVC cable, using Formula (6):

Tp=0.25+0.25t=0.25+0.25X0.5 (25 cycle=25/50=0.5)

mm2
Considering above items (a,b&c) the cable 18x(1x400mm2) is selected.

Note:

Calculations for the rest of cables, is submitted in attachment.

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Table 1
Rating factors for variation of ground temperature for cables laid direct in the ground

Ground tempretureC 10 15 20 25 30 35 40
Rating Factor
(maximum conductor 1.03 1 0.97 0.93 0.89 0.86 0.82
tempreture 90oC)

Table 2
Rating factors for variation in ambient air temperature

Ground tempretureC 25 30 35 40 45 50 55
Rating Factor
(maximum conductor 1 0.96 0.92 0.88 0.83 0.78 0.73
tempreture 90oC)

Table 3
Rating Factors for Depth of Laying for Cables Laid Direct in The Ground

Depth of LV Cables MV Cables

Laying, Up to 70mm2 above Up to above
Meter 50mm2 to 300 mm2 300 mm2 300mm2 300 mm2
0.05 1.00 1.00 1.00 -
0.06 0.99 0.98 0.97 -
0.80 0.97 0.96 0.94 1.00 1.00
1.00 0.95 0.93 0.92 0.98 0.97
1.25 0.94 0.92 0.89 0.96 0.95
1.50 0.93 0.90 0.87 0.95 0.93
1.75 0.92 0.89 0.86 0.94 0.91
2.00 0.91 0.88 0.85 0.92 0.89
2.50 0.90 0.87 0.84 0.91 0.88
3.0 or more 0.89 0.85 0.82 0.90 0.86
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MV & LV POWER CABLE Rev. No.: 2
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TABLE 4-1
Rating Factor for Variation in Thermal Resistivity of Soil
Twin of Multi-Core Cables Laid in The Ground

Nominal Area
Value of oK.m / W
of Conductor
mm2
0.7 0.8 0.9 1.0 1.5 2.0 2.5 3.0 3.5 4.0
1.5/2.5 1.12 1.09 1.07 1.04 0.94 0.86 0.80 0.75 0.70 0.66
4 1.13 1.10 1.07 1.05 0.94 0.85 0.79 0.74 0.69 0.65
6 1.14 1.10 1.07 1.05 0.93 0.85 0.79 0.74 0.68 0.64
10 1.15 1.11 1.08 1.05 0.93 0.85 0.78 0.73 0.67 0.63
16 1.66 1.12 1.08 1.05 0.93 0.84 0.77 0.72 0.66 0.62
25 1.17 1.13 1.09 1.05 0.93 0.83 0.77 0.71 0.65 0.61
35 1.17 1.13 1.09 1.06 0.92 0.83 0.76 0.71 0.65 0.61
50 1.17 1.14 1.09 1.06 0.92 0.83 0.76 0.71 0.65 0.61
70 1.18 1.14 1.09 1.06 0.92 0.83 0.75 0.70 0.64 0.60
95 1.18 1.14 1.09 1.06 0.92 0.83 0.75 0.70 0.64 0.60
120 1.19 1.14 1.10 1.06 0.92 0.82 0.75 0.69 0.64 0.60
150 1.19 1.14 1.10 1.06 0.92 0.82 0.75 0.69 0.63 0.59
185 1.19 1.14 1.10 1.06 0.92 0.82 0.74 0.69 0.63 0.59
240 1.20 1.15 1.10 1.07 0.92 0.81 0.74 0.69 0.63 0.59
300/400 1.20 1.15 1.10 1.07 0.92 0.81 0.74 0.69 0.63 0.59

Table 4-2
Rating Factors for Variation in Thermal Resistivity of Soil for
Two or Three Single Core Cables Laid in The Ground

Nominal Area
Value of oK.m / W
of Conductor
mm2
0.7 0.8 0.9 1.0 1.5 2.0 2.5 3.0 3.5 4.0
120 1.22 1.16 1.12 1.07 0.91 0.81 0.73 0.68 0.63 0.59
150 1.22 1.16 1.12 1.07 0.91 0.81 0.73 0.68 0.63 0.59
185 1.22 1.17 1.12 1.07 0.91 0.81 0.73 0.68 0.63 0.59
240 1.23 1.17 1.12 1.07 0.91 0.81 0.73 0.68 0.63 0.59
300 1.23 1.17 1.12 1.07 0.91 0.81 0.73 0.68 0.63 0.59
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MV & LV POWER CABLE Rev. No.: 2
SIZING STUDY
Table 5-1
Group Rating Factors for Twin or Multi-Core
Cables in Tier Formation, Laid Direct in the Ground

Formation of Cables

Spacing of
Cables
(meter)

Touching 0.69 0.62 0.53 0.44 0.40

LV CABLE

0.15 0.77 0.71 0.62 0.53 0.48

0.30 0.81 0.77 0.68 0.58 0.53
0.45 0.83 0.80 0.72 0.62 0.56
0.60 0.85 0.82 0.74 0.64 0.59

Touching 0.68 0.61 0.52 0.43 0.38

MV CABLE

0.15 0.75 0.69 0.59 0.50 0.46

0.30 0.79 0.74 0.65 0.55 0.50
0.45 0.81 0.77 0.68 0.58 0.53
0.60 0.83 0.79 0.71 0.61 0.65
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Table 5-2
Group Rating Factors for Twin or Multi-Core
Cables in Tier Formation, Laid Direct in the Ground

Formation of Cables

Spacing of
Cables
(meter)

Touching 0.66 0.59 0.53 0.49

LV CABLE

0.15 0.71 0.65 0.58 0.55

0.30 0.76 0.71 0.63 0.60
0.45 0.79 0.74 0.66 0.63
0.60 0.80 0.77 0.68 0.65

Touching 0.66 0.59 0.53 0.49

MV CABLE

0.15 0.70 0.64 0.77 0.54

0.30 0.74 0.69 0.62 0.59
0.45 0.77 0.72 0.65 0.62
0.60 0.79 0.74 0.67 0.64
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Table 6
30 KV Power Cable According To IEC 60502
Reduction Factors for Groups of More Than One Circuit of Single Core Cables
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Table 7-1
LV Power Cable According To IEC 60502
Rating Factors for Multi Core Cable in Tray, Horizontal formation
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Table 7-2
LV Power Cable According To IEC 60502
Rating Factors for Single Core Cable in Tray, Horizontal formation
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Attachment- Cable Sizing Study