CABLE SIZING CALCULATION AND REPORT FOR MV AND LV MOTOR FEEDERS

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1. Introduction:
This document presents a report on cable sizing calculation for the Ras Tanura Intigrated Project. The design calculation aims at appropriate selection of cables considering the installation conditions, ambient temperature, group de-rating and short circuit withstand. The cable sizes and the maximum cable lengths are calculated based on continuous current rating, ensuring voltage drop is within permissible limits and are checked for thermal short circuit capacity. Cable selection charts have been prepared and are annexed for reference.

2. Standards And Specifications :
A554-K-PRG-EL-GEN-PHL-005 A554-K-PRG-PE-GEN-PDD-001 G7Z-0001-00 G7C-0302-00 RT7D-0665-00 RT7D-0613-00 Electrical Design Philosophy Project Design Data Electrical Design Engineering Criteria Process Plant Cabling / Wiring Methods. Form Wound Motors. Squirrel Cage Induction Motors NEMA Frame Horizontal and Vertical Totally Enclosed Designs 600 Volts and below.

3. References :
XXXX XXXX A554-K-299-EL-DWG-EA1-001 Electrical System Study Report Grounding Philosophy and Calculations Electrical Overall One-Line Diagram (SS-299C001) Riyadh Cable Catalogue Ducab Cable Catalogue

4. Specification Requirements:
As per clause 10.1.1 of A554-K-PRG-EL-GEN-PHL-005 “The voltage at any point on the RTIP system will normally remain within the nominal values as stated below, unless abnormal conditions prevail. Under exceptional circumstances, the maximum over voltage limits stated below should not be exceeded for more than 30 minutes.” • • Nominal range 30 min over voltage +/+ 5% 10%

As per clause 10.2.2 of A554-K-PRG-EL-GEN-PHL-005 “The maximum voltage drop (measured on the distribution bus) under motor starting or restarting conditions should not exceed 10% of nominal voltage. Voltage drop at the motor terminal shall not drop below 85% of the rated motor voltage.” As per clause 26.1.1 of A554-K-PRG-EL-GEN-PHL-005 “All cables shall be routed above ground in continuous tray systems. Underground cable installations shall be by exception and require Owner Electrical SME approval.” As per clause 26.1.2 of A554-K-PRG-EL-GEN-PHL-005 “All low voltage and instrument cables shall be supplied according to IEC standards. Cable jackets shall be flame retardant, UV rated for direct sunlight exposure and suitable use in cable tray. Cable shall be steel wire armoured”.

02 ohm (Typical Value) Allowable voltage drops (starting and running) for LV and MV motors: 15 % and 5% respectively. Calculation . 1 sec 65kA. 5. for LV motors Brook Crompton ANSI motor catalogue has been used. Basis of Design: The system design parameters and the site ambient conditions are listed below.5 mm2 Riyadh Cable data has been used for MV motor feeders and Ducab Cable data has been used for LV motors. For Motor details of MV motors ABB ANSI motor catalogue has been used. • Nominal Bus Voltage Levels Medium Voltage Low Voltage 4160 V. • 6.3 of A554-K-PRG-EL-GEN-PHL-005 PAGE 2 OF 11 REV .1.2 -1 OF 11 “The maximum conductor operating temperature under normal conditions shall not exceed 90 degree Centigrade. The maximum conductor temperature under short circuit conditions shall not exceed 250 degree centigrade based on maximum cable fault duration of 250 ms”. 3-phase. Minimum conductor sizes at various voltage levels : • Medium Voltage motor feeder Low Voltage motor feeder • 25 mm2 2. Under emergency conditions the conductor shall not exceed 130 degree centigrade. 3-phase 480 V. 1 sec : : 60 Hz 500 C • • Zsystem : 0.CABLE SIZING CALCULATION AND REPORT FOR MV AND LV MOTOR FEEDERS As per clause 26.3 Wire • • • System Frequency Site ambient air temperature Fault Levels at various voltage levels Medium Voltage Low Voltage 50kA.

Cable Operating Voltage.F – – – FLC xS . 1D separation) = = 0. SIZING CRITERION – A Cables feeding a single motor used in a continuous duty application shall have an ampacity of not less than Service Factor times the motor’s full load current rating. Motor Service Factor 1. Voltage drop in the cable. Normal Ampacity required = Where.F DF (A) Motor Full Load Current. FLC S.F – – – Rated kW of the motor. Motor Power Factor.3 -1 OF 11 • MV Motor Feeder Cable Sizing Calculation The sizing of 4.0 kV motor feeder cables shall take into account the following parameters: a) b) c) Current carrying capacity of cable. Short circuit withstand capacity.Fxefficien cy (A) Where.85 . De-rating Factor a) Ambient air temperature factor (500 C) b) Grouping factor ( 5 cables in group 3 core 1 layer.F D.1) De-rating factor (based on cable laying conditions) The motor full load current can be calculated as follows: I= kW 3 xkVxP . kW V P. These cables are sized to account for the minimum thermal rating required by applying the de-rating factors based on the laying conditions and the maximum short circuit withstand capability of the cable has to be chosen greater than 50 kA ( for circuit breaker protected feeders).82 0.0 (as per RT7D-0665-00 clause 4. The maximum feeder length is guided by the voltage drop calculations.CABLE SIZING CALCULATION AND REPORT FOR MV AND LV MOTOR FEEDERS PAGE 3 OF 11 REV . Therefore the cable should be chosen such that the normal ampacity meets this criterion.

The minimum cross section of the cable – A= Ix t K Where.93 41 (A) (224kW is the rating of the motor) Now the cable ampacity required to feed the above motor is calculated as: Ampacity required = FLC xS . Based on the calculations above it can be concluded that 1R X 3C X 25mm2 cable can feed 300 HP motor feeder.F DF 41 x1.85 0. A K T – – – Minimum Area of cross section required for 4. Insulation coefficient of XLPE cable.Fxefficien cy I= 224 = 3 x 4 x0.70 (A) = = 58.0 0.70.82 X 0. .57 (A).16 kV cable system. 1R X 3C X 25mm2 cable has a non de-rated ampacity of 150 (A). Total fault clearing time in second.84 x.CABLE SIZING CALCULATION AND REPORT FOR MV AND LV MOTOR FEEDERS c) Overall de-rating factor = = = PAGE 4 OF 11 REV aXb 0. SIZING CRITERION – B The short circuit withstand capacity of the cable determines the minimum cross section area of the cable which can be used. This is the minimum cable size available for MV feeders.4 -1 OF 11 Now for a 300 HP motor feeder the following calculation demonstrates the selection of cable cross section based on SIZING CRITERION A: The motor full load current can be calculated as : I= kW (A) 3 xkVxP . .

K is the insulation coefficient of XLPE insulated cable = 143. Then the Minimum Area of the cable for 4.16kV switchgear is 50 kA.5 -1 OF 11 Total Tripping time of 4. The insulation coefficient of XLPE cables is 143.CABLE SIZING CALCULATION AND REPORT FOR MV AND LV MOTOR FEEDERS I – Fault current rating of the switchgear.16kV switchgear is 50 kA. .16 kV Circuit Breaker = 200 ms (Typical value) The maximum fault rating of the 4.2 143 The maximum fault rating of the 4.005 sec.005 143 = 24. FOR FUSE PROTECTED FEEDERS : The Fuse rupturing time = 0.16 kV cable system. The insulation coefficient of XLPE cables is 143.72 mm2 25 mm2 being the nearest available standard cross section is chosen to be the minimum cross section of cables for fuse protected motor feeders.16 kV cable system. The admissible current density D in short circuit conditions is given by the formula: A= Ix t K Where A is the minimum Area of cross section required for 4.16 kV system A = = 156. K is the insulation coefficient of XLPE insulated cable = 143.36 mm2 185 mm2 being the nearest available standard cross section of cable available is chosen to be the minimum cross section of the cable. So it can be concluded that for fuse protected feeders all cable sizes can be used and for breaker operated feeders minimum cable size which can be selected is 185 mm2. Then the Minimum Cross Section Area of the cable for 4. 50000 x 0. PAGE 5 OF 11 REV . The admissible current density D in short circuit conditions is given by the formula: A= Ix t K Where A is the minimum Area of cross section required for 4.16 kV system A = 50000 x 0.

Cable Resistance Ohm/km Cable Reactance Ohm/km Number of cables running in parallel. For motor feeders voltage drop criteria needs to be checked for both running and starting conditions. Voltage drop in a motor feeder can be expressed as follows: Vd running = 3 xI m ( R cos φr + X sin φr ) xL 1000 x N C 3 xI lrc ( R cos φst + X sin φst ) xL 1000 x N C (V) Vd starting = (V) Where. cosΦst – R X Nc – – – The maximum length of cable which can be used maintaining the prescribed voltage drop limits is calculated as follows: m running =         ( ( Vd x N C 3 xI m x ( R cos φr + X sin φr ) )   x1000 (m)     x1000 (m)   m starting = Vd x N C 3 xI lrc x( R cos φst + X sin φst ) ) . Im Ilrc cosΦr – – – Rated current of motor.CABLE SIZING CALCULATION AND REPORT FOR MV AND LV MOTOR FEEDERS PAGE 6 OF 11 REV . Motor starting power factor.6 -1 OF 11 SIZING CRITERION – C The cable impedence causes a voltage drop at the load terminal. The following checks are performed towards achieving the above. the same needs to be arrested within the permissible limits. Locked Rotor current of the motor. Motor power factor for running condition.

7 -1 OF 11 The permissible running and starting voltage drops are 5% and 15% respectively. . These cables are sized to account for the minimum thermal rating required by applying the de-rating factors based on the laying conditions and the voltage drop limitations.146 x 0.CABLE SIZING CALCULATION AND REPORT FOR MV AND LV MOTOR FEEDERS PAGE 7 OF 11 REV .927 x 0.5 x( 0.22 + 0.927 x0. As suggested above the same cable would not be suitable for feeding the same motor feeder in the event the feeder is circuit breaker protected. When feeding a 300 HP motor with 1R X 3C X 25 mm2 cable the maximum running and starting lengths are: mrunning =    ( 4000 x5 x 1 3 x 41 x ( 0. Based on the above calculations it is concluded that a fuse protected 300 HP motor feeder can be fed with a single run of 3 core 25 mm2 cable to a maximum length of 3283 m satisfying the running and the starting voltage drops.54 ) x100 )  x1000   = 3283 m.84 + 0. Voltage drop in the cable.975 ) x100 )  x1000   = 3778 m. Therefore the cable should be chosen such that the normal ampacity meets this criterion. • LV Motor Feeder Cable Sizing Calculation Sizing of 460 volt motor feeder cables shall take into account the following parameters: a) b) Current carrying capacity of the cable. mstarting =    ( 4000 x15 x 1 3 x 266 . SIZING CRITERION – A Cables feeding a single motor used in a continuous duty application shall have an ampacity of not less than Service Factor times the motor’s full load current rating.146 x0.

Motor Service Factor 1.46 x0.5 = 3 x 0.F DF (A) . Now for a 10 HP motor feeder the following calculation demonstrates the selection of cable cross section based on SIZING CRITERION A: The motor full load current can be calculated as: I= kW (A) 3 xkVxP .2) De-rating factor (based on cable laying conditions) The motor full load current can be calculated as follows : I= kW (A) 3 xkVxP .82 1 aXb 0. FLC S.CABLE SIZING CALCULATION AND REPORT FOR MV AND LV MOTOR FEEDERS PAGE 8 OF 11 REV .F D. kW V P.Fxefficien cy Where. Motor Power Factor.F – – – FLC xS .15 ( as per RT7D-0613-00 clause 2.5kW is the rating of the motor) Now the cable ampacity required to feed the above motor is calculated as: Ampacity required = FLC xS .F – – – Rated kW of the motor. Cable Operating Voltage.Fxefficien cy I= 7 .82 X 1 0.895 12.82.F (A) DF Motor Full Load Current.5 (A) (7.8 -1 OF 11 Normal Ampacity required = Where.84 x. De-rating Factor a) Ambient air temperature factor (50 degree C) b) Grouping factor for multi core cables laid in air c) Overall de-rating factor = = = = = 0.

Motor power factor for running condition. 1RX 4CX 2.53 (A). Im Ilrc cosΦr – – – Rated current of motor.5 x1.82 = 17. Voltage drop in a motor feeder can be expressed as follows: Vd running = 3 xI m ( R cos φr + X sin φr ) xL 1000 x N C 3 xI lrc ( R cos φst + X sin φst ) xL 1000 x N C (V) Vd starting = (V) Where. Motor starting power factor. For motor feeders voltage drop criteria needs to be checked for both running and starting conditions.5 mm2 cable can feed 10 HP motor feeder. This is the minimum cable size available for LV feeders. the same needs to be arrested within the permissible limits. Based on the calculations above it can be concluded 1RX 4CX 2.15 0. The following checks are performed towards achieving the above.9 -1 OF 11 = 12 .5 mm2 cable has a non de-rated ampacity of 33 ampere. SIZING CRITERION – B The cable impedence causes a voltage drop at the load terminal. Locked Rotor current of the motor. cosΦst – R X Nc – – – The maximum length of cable which can be used maintaining the prescribed voltage drop limits is calculated as follows: . Cable Resistance Ohm/km Cable Reactance Ohm/km Number of cables running in parallel.CABLE SIZING CALCULATION AND REPORT FOR MV AND LV MOTOR FEEDERS PAGE 9 OF 11 REV .

50 x( 9. When feeding a 10 HP motor fed with 1RX 4CX 2. So based on the calculations above it can be concluded that a 10 HP motor can be fed by a 1RX 4CX 2.5 m Based on the comparison made between the length based on voltage drop. .84 + 0.45 x0.87 m m starting =     460 x 1x15 3 x81 x( 9.121 x0.5 mm2 cable up to a maximum length of 94.CABLE SIZING CALCULATION AND REPORT FOR MV AND LV MOTOR FEEDERS PAGE 10 OF 11 REV .45 x 0.84 ) x100 )  x1000 m   = 94.121 x0.5 m.10 -1 OF 11 m running =         ( ( Vd x N C 3 xI m x ( R cos φr + X sin φr ) )   x1000 (m)     x1000 (m)   m starting = Vd x N C 3 xI lrc x( R cos φst + X sin φst ) ) The permissible running and starting voltage drops are 5% and 15% respectively.54 ) x100 )  x1000 m   =132. LV cable short circuit capabilities: The cable short circuit current capabilities is based upon the adiabatic equation given by T=( k2 X s2)/I2 Where cable withstand capability is given by (k2 X s2) = A2 Where k is the cable insulation thermal constant (143 for XLPE insulated cables) and s is the cable cross section in mm2. the maximum cable length is taken as the shorter of the two.54 + 0.5 mm2 cable the maximum running and stating lengths are: m running =     ( ( 460 x 1x5 3 x12 .

7 kA. then by viewing horizontally. while the fuse let through current stands at 5. For motor feeders. the criterion which determines the maximum permissible cable length is displayed by the side as (=T=) when the thermal limit of the cable is exceeded and a larger cable is required. For the motor feeders. Now for feeding a 15 HP motor with a 2. Cable Selection Chart : Cables are selected by locating the motor kW rating under the relevant Data column. The cable current carrying capacity after applying a de-rating factor is compared with the Motor FLC.06 kA.5 mm2 cable can feed motors up to 10 HP. this is normally set to Service Factor times the motor full load current) ICABLE x F > ITHS ICABLE F ITHS Cable current rating De-rating factor Thermal relay setting If the duty exceeds the cable de-rated capability then a =T= is displayed in the chart. Viewing up this column indicates the minimum allowable cable size. this is denoted by a {s} or {r} alongside the figures on the sheet. So the only restriction is 2. For Breaker fed MV motors a =T= is also displayed even if the short circuit capability of the cable is exceeded. . the first record displayed that exceeds the known cable route length is selected. {R} when voltage drop at running condition determines the length (for motors). (=L=) when the cable exceeds the specified maximum length Also {S} when voltage drop at starting dictates the length (for motors).005 sec is 5.11 -1 OF 11 The cable of chosen cross-section and the short circuit capacity is checked to determine if it is capable of withstanding the let-through energy of the connected protective device. (In case of motors. The following formula is used within the spreadsheet.5 mm2 it can be checked that the cable withstand for 0. 7.CABLE SIZING CALCULATION AND REPORT FOR MV AND LV MOTOR FEEDERS PAGE 11 OF 11 REV . the spreadsheet determines whether the starting conditions or the running conditions determine the maximum permissible cable.

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