HV CABLE SELECTION CALCULATION

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INDEX Clause No. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00 INTENT CRITERIA FOR SELECTION OF CABLE DESIGN DATA MINIMUM CROSS SECTION AREA CALCULATIONS MINIMUM PERMISSABLE CURRENT RAITINGS VOLTAGE DROP CALCULATION SAMPLE CALCULATION Description

Page No. 2 2 2 3 3 4 4

REFERENCE DOCUMENTS: 1) Data sheet of M/s Polycab.(Annexure-I) ENCLOSURES: 1) Feeder wise percentage voltage drop figure.

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HV CABLE SELECTION CALCULATION

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1.00.00

INTENT This document is intended to cover the sample voltage drop calculation for CWP Motor, BFP Motor, Outgoing to Ash handling Transformer & Station Service transformer and Tie to SS.

2.00.0

CRITERIA FOR SELECTION OF CABLES: Fault Current withstand capability. Current rating for continuous operation. Maximum Permissible voltage drop: 15% during starting. 5% during normal running conditions.

3.00.00 3.00.01

DESIGN DATA Motor rated current has been calculated as per following formula Motor Rated Current =(kW x 1000) / (1.732 x 6600 x Power Factor x Efficiency)

3.00.02

Motor starting current is taken as 6 times the rated current for CWP Motor. Motor starting current is taken as 4.5 times the rated current for BFP Motor. DERATING FACTORS The following De-rating Factors have been considered.

3.00.03

Single Core Cables Cable Laid in cable Trays/Trench Temperature Correction Factor, K1 Group Factor, K2 for XLPE Cable Three Core Cables Cable Laid in cable Trays/Trench Temperature Correction Factor, K1 Group Factor, K2 for XLPE Cable 0.89 0.79 0.89 0.80

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HV CABLE SELECTION CALCULATION

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4.00.0

MINIMUM CROSS SECTION AREA FOR FAULT CURRENT WITHSTAND CAPACITY Depending upon the faut current magnitude and duration, the minimum conductor size shall be arrived using formula: A = Ik x K1x K2 x t

where, Ik A t = Fault current in kA (40) = Minimum cross section area required in Sq. mm = Duration of fault current in second. 0.16 sec for Out going feeder 1 sec for Tie feeder K1 K2 T1 T2 K2 = Constant (6.76 For Alminium) = log((+T2)/( +T1))-1/2 = temperature coefficient of electrical resistance at zero deg. C (228 For Al) = Initial temp before short circuit in deg. C(90 for XLPE) = Final temp. After short circuit in deg. C (250 for XLPE) =log((228+250)/(228+90))-1/2 = 1.56 Minimum cross section area required for Tie feeder (A) = 40x 6.76x 1.56x1 = 421.82 Sq.mm

Selected cross section area for tie feeder is 630 Sq. mm Minimum cross section area required for Outgoing feeder (A) = 40x 6.76x 1.56x0.16 = 168.72 Sq.mm Selected cross section area for outgoing feeder is 185 Sq. mm

5.00.00

PERMISSIBLE CURRENT RATINGS

The de-ration effect due to temperature correction and grouping has been considered by increasing the full load current by the factors imposed by these conditions. These increased current values are compared with the rated current carrying capacity of the cable. Hence Rated current carrying capacity of the cable must be greater than the load current after derating factor.

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HV CABLE SELECTION CALCULATION

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6.00.00

Voltage Drop calculation % V = 3 x ILs x L x (Rac Cosi + X Sini) start / 10 x VS x N (for motor feeder) % V = 3 x ILr x L x (Rac Cos + X Sin) run / 10 x VS x N

where, VS ILr ILs Rac X L = Line voltage. = Line current-running. = Line current-starting.(for motor feeder) = AC resistance per km. = Reactance per km. = Route length in Meters.

Cos = Running power factor Cos i = Starting power factor N 7.00.00 = No. of Runs

SAMPLE CALCULATIONS

7.01.00 Motor feeder - Cable from Station Switchgear to CW Pump motor Current capacity check Rating = 1650 kW Voltage, Vs = 6600 V Power Factor = 0.81 Efficiency = 0.96 Full Load current ILr Starting current ILs = (kW x 1000) / (1.732 x 6600 x Power Factor x Efficiency) = (1650 X 1000) / (1.732 X 6600 X 0.81 X 0.96) = 186 Amps. = 6 * 186

= 1116 Amps.

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Temperature correction factor, K1 Group factor, K2 Total Derating factor

=0.89 =0.79 = 0.89 * 0.79 = 0. 7031 = 186/ 0.7031 = 264 Amps = 3C- 185sq.mm.

Hence load current after Derating factor Cable selected Hence only one run is sufficient.

Rated current carrying capacity of the cable = 335 Amps Since (Rated current carrying capacity of the cable) > (load current after Derating factor) Voltage drop calculation. - Normal running % V = 3 x ILr x L x (Rac Cos + X Sin) run / 10 x VS x N Resistance per km of 3C-185 Sq. mm. cable, R Reactance per km of 3C-185 Sq. mm. cable, X Length = 0.1885% Since (Percentage drop) < (5%) Cable selected is OK for running conditions - During starting Starting current = 1116 Amps. Sini = 0.98 % V = 3 x ILs x L x (Rac Cosi + X Sini) start / 10 x VS x N % V = 3 x 1116 x 350 x (0.21 x 0.2 + 0.087 x 0.98) start / 10 x 6600x2 = 0.6508% Since (Percentage starting drop) < (15%) Cable selected is OK for start condition. 7.02.00 Motor feeder - Cable from Station Switchgear to BFP motor Current capacity check Rating = 4000 kW Page 5 of 9 Starting power factor, Cosi = 0.2 = 0.21 = 0.087 = 350m

% V = 3 x 186 x 350 x (0.21 x 0.81 + 0.087 x 0.586) run / 10 x 6600x2

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Voltage, Vs = 6600 V Power Factor = 0.93 Efficiency = 0.92 Full Load current ILr Starting current ILs = (kW x 1000) / (1.732 x 6600 x Power Factor x Efficiency) = (4000 X 1000) / (1.732 X 6600 X 0.93 X 0.92) = 409 Amps. = 4.5 * 409 = 1841 Amps. =0.89 =0.79 = 0.89 * 0.79 = 0. 7031 Hence load current after Derating factor Cable selected Number of runs required Next higher integer is 2. Hence two run of 3C-300 Sq. mm cable considered Current of 2 runs of 3C- 400 Sq. mm. = 2 x 450 = 900 Amps. Since (Rated current carrying capacity of the cable) > (load current after Derating factor) Voltage drop calculation. - Normal running % V = 3 x ILr x L x (Rac Cos + X Sin) run / 10 x VS x N Resistance per km of 3C-300 Sq. mm. cable, R Reactance per km of 3C-300 Sq. mm. cable, X Length = 0.0881% Since (Percentage drop) < (5%) Cable selected is OK for running conditions Page 6 of 9 = 0.128 = 0.082 = 110 m = 409/ 0.7031 = 581 Amps = 3C- 300sq.mm. = 484/450 = 1.074 Rated current carrying capacity of the cable = 450 Amps

Temperature correction factor, K1 Group factor, K2 Total Derating factor

% V = 3 x 409 x 110 x (0.128 x 0.93 + 0.082 x 0.367) run / 10 x 6600x2

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- During starting Starting current Starting power factor, Cosi Sini = 1841 Amps. = 0.2 = 0.98

% V = 3 x ILs x L x (Rac Cosi + X Sini) start / 10 x VS x N % V = 3 x 1841 x 110 x (0.128 x 0.2 + 0.082 x 0.98) start / 10 x 6600x2 = 0.2814% Since (Percentage starting drop) < (15%) Cable selected is OK for start condition. 7.03.00 Cable from Station Switchgear to Ash Handling Transformer.

Current capacity check Rating = 1.6 MVA Voltage, Vs = 6600 V Full Load current ILr Group factor, K2 Total Derating factor = (MVA x 1000) / (1.732 x 6.6) = (1.6 X 1000) / (1.732 X 6.6) = 140 Amps. =0.89 =0.79 = 0.89 * 0.79 = 0.7031 Hence load current after Derating factor Cable selected Hence only one run is sufficient. Since (Rated current carrying capacity of the cable) > (load current after Derating factor) = 140/ 0.7031 = 200 Amps = 3C- 185sq.mm. Rated current carrying capacity of the cable = 335 Amps Temperature correction factor, K1

Voltage drop calculation. - Normal running % V = 3 x ILr x L x (Rac Cos + X Sin) run / 10 x VS x N Page 7 of 9

HV CABLE SELECTION CALCULATION

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Resistance per km of 3C-185 Sq. mm. cable, R Reactance per km of 3C-185 Sq. mm. cable, X Length = 0.1895% Since (Percentage drop) < (5%)

= 0.21 = 0.087 = 230m

% V = 3 x 140 x 230 x (0.21 x 0.85 + 0.072 x 0.526) run / 10 x 6600x1

Cable selected is OK for running conditions 7.04.00 Outgoing feeder - Cable from Station Switchgear to Station Service TRF Current capacity check Rating = 2.5 MVA Voltage, Vs = 6600 V Full Load current ILr Group factor, K2 Total Derating factor = (MVA x 1000) / (1.732 x 6.6) = (2.5 X 1000) / (1.732 X 6.6) = 219 Amps. = 0.89 = 0.79 = 0.89 * 0.79 = 0. 7031 Hence load current after Derating factor Cable selected Hence only one run cable is sufficient. Since (Rated current carrying capacity of the cable) > (load current after Derating factor) Voltage drop calculation. - Normal running % V = 3 x ILr x L x (Rac Cos + X Sin) run / 10 x VS x N Resistance per km of 3C-300 Sq. mm. cable, R Reactance per km of 3C-300 Sq. mm. cable, X Length = 0.0708% Since (Percentage drop) < (5%) = 0.21 = 0.087 = 55m = 219/ 0.7031 = 311 Amps = 3C- 185sq.mm. Rated current carrying capacity of the cable = 335 Amps Temperature correction factor, K1

% V = 3 x 219 x 55 x (0.21 x 0.85 + 0.087 x 0.526) run / 10 x 6600x1

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7.05.00 Outgoing feeder - Cable from Station Switchgear to Tie feeder Current capacity check Full Load current ILr = 3150 Amps Temperature correction factor, K1 Group factor, K2 Total Derating factor = 0.89 = 0.80 = 0.89 * 0.80 = 0. 712 Hence load current after Derating factor Cable selected Number of runs required Next higher integer is 6. Hence six run considered. Current of 6 runs of 1C- 630 Sq. mm. = 6 x 840 = 5040 Amps Since (Rated current carrying capacity of the cable) > (load current after Derating factor) Voltage drop calculation. - Normal running % V = 3 x ILr x L x (Rac Cos + X Sin) run / 10 x VS x N Resistance per km of 3C-185 Sq. mm. cable, R Reactance per km of 3C-185 Sq. mm. cable, X Length = 0.1704% Since (Percentage drop) < (5%) = 0.0469 = 0.092 = 140 m = 3150/ 0.712 = 4424 Amps = 1C- 630sq.mm. = 4424/840 = 5.26 Rated current carrying capacity of the cable = 840 Amps

% V = 3 x 3150 x 140 x (0.0469 x 0.85 + 0.092 x 0.526) run / 10 x 6600x6

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