Power carrier selection

Part 2 – Current calculations

  Current symbols and definitions.
 Current calculation formula.
 Fast current calculations.
 Switchgear sizing.
 Cable sizing.
Content  Derating factors – El Sewedy.
 Derating factors – EC.
 Static loads.
 Dynamic loads.

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 At first recognize the following :
𝒊𝒃 : Rated current (Actual load current).
𝒊𝒏 𝒐𝒓 𝒊𝒓 : Nominal current (switchgear size).
𝒊𝒛 : Cable withstand-ability.
Current
symbols and Where : 𝒊𝒛 > 𝒊𝒏 > 𝒊𝒃

definitions

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  How to calculate the rated (actual) current ?

𝑆 𝑃
 𝒊𝒃 = =
3𝑉 3 𝑉 𝑐𝑜𝑠(φ)

Current
calculation Where :
 S : apparent power (KVA).
formula  P : real power (KW).
 V : line to line voltage (v).
 Cos (φ) : load power factor .

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 Assume 380 V network with an average load PF of 0.8

3φ
Power Approximate current (A) Exact current (A)
kVA 1.5 1.52
HP (PF=0.8) 1.5 1.42

Fast Current kW (PF=0.8) 2 1.9

calculations 1φ
Power Approximate current (A) Exact current (A)
kVA 4.5 4.55
HP (PF=0.8) 4.5 4.24
kW (PF=0.8) 6 5.68
Notes:
1. 1 horse power = 0.746 kW.
2. Copper current carrying capacity CCC ≈ 5 A/𝑚𝑚2 .
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Switchgear
Sizing

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  𝒊𝒏 = 𝒊𝒃 ∗ 1.25 (according to NEC) (then approach the nearest standard).

 Notes:
 This rule is applicable for CB, Fuse, LBS, DS.
Switchgear  For PFC panels CB rating is 𝒊𝒏 = 𝒊𝒃 ∗ 1.35 (or 𝒊𝒏 = 𝒌𝑽𝑨𝑹 ∗ 𝟐).
Sizing  For Contactors 𝒊𝒏 = 𝒊𝒃 ∗ 1.5 .

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Cable sizing

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 𝒊𝒏
 𝒊𝒛 = (then approach the nearest standard).
𝑫𝑭
 DF (Derating Factor / Reduction Factor / Correction Factor):
 The derating factor is a safety factor applied to correct the current
calculations according to the actual operating conditions deviated from the
standard conditions.
Cable sizing  Those factors are used to compensate for:
1. Thermal derating.
2. Proximity effect.
3. Burial depth and soil thermal resistivity.
 The overall DF = DF1 * DF2 * …
 Cables: If the operating conditions are not known, we may assume DF=0.8.
 Bus ducts: we may assume DF=1.

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 Standard operating conditions:

Derating
factors

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Derating
factors

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Derating
factors

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Derating
factors

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Derating
factors

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Derating
factors

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Derating
factors

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Egyptian code
specs

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Egyptian code
specs

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Egyptian code
specs

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Egyptian code
specs

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Egyptian code
specs

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Egyptian code
specs

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Egyptian code
specs

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Egyptian code
specs

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Egyptian code
specs

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Egyptian code
specs

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Egyptian code
specs

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 MDB (TDDL)

Design load
SMDB (TDDL)

DB (TDL)

Branch circuit (TCL)

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  For static loads the feeder and breaker are sized as the following:

 For branch circuits we consider TCL (total connected load) and use wires.
 We calculate current as previously elaborated then choose the convenient
wire / cable size.
 Notes:
1. Minimum CSA for lighting circuits is 3 mm².
Static loads 2. Minimum CSA for power circuits is 4 mm².
 Common practice:
1. For lighting branch circuits minimum CB rating is 16A.
2. For power branch circuits minimum CB rating is 20A
3. For LP minimum incoming CB is 40A MCCB.
4. For PP minimum incoming CB is 63A MCCB.

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  DB:
 Calculate the TCL
 Apply the suitable demand factor (to get TDL).
 Size the main incoming feeder and breaker accordingly

 SMDB:
 Calculate the TDL (= sum of connected panels ).
Static loads  Apply the suitable diversity factor (to get TDDL).
 Size the main incoming feeder and breaker accordingly.

 MDB:
 Calculate the TDDL (= sum of connected panels ).
 Size the main incoming feeder and breaker accordingly.

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 • Motors have a major drawback through operation which is the high
starting current.

Dynamic
loads

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Locked rotor
current
(kVA code)

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 Direct online – DOL | 𝐼𝑠𝑡 is up to 9𝐼𝑟 (allowed only up to 15 Hp – A.K.A. small motors)

Motor starters

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 1
Star delta starter – 𝑌/∆ | 𝐼𝑠𝑡 = 3 𝐼𝑠𝑡 𝐷𝑂𝐿

Motor starters

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 1
Autotransformer starter - 𝐼𝑠𝑡 = 4 𝐼𝑠𝑡 𝐷𝑂𝐿 (adjustable) .

Motor starters

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 Soft starter | 𝐼𝑠𝑡 ≈ 1.5: 2 𝐼𝑟

Motor starters

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 VFD (variable frequency drive) | 𝐼𝑠𝑡 ≈ 𝐼𝑟 (constant torque operation)

Motor starters

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 Dynamic
loads circuit
design
Large motors are
equipped with starter
and overload protection

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 Dynamic
loads circuit
design ‫ كتاب التمديدات‬: ‫المصدر‬
‫ الجيالني‬.‫الكهربية – د‬

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 Dynamic
loads circuit
design ‫ كتاب التمديدات‬: ‫المصدر‬
‫ الجيالني‬.‫الكهربية – د‬

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 Dynamic
loads circuit
design
‫ كتاب التمديدات‬: ‫المصدر‬
‫ الجيالني‬.‫الكهربية – د‬

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 NEC
430.53(C)(4)

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NEC
430.52

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 Dynamic
loads circuit
design

‫ كتاب التمديدات‬: ‫المصدر‬

‫ الجيالني‬.‫الكهربية – د‬

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 Dynamic
loads circuit
design

‫ كتاب التمديدات‬: ‫المصدر‬

‫ الجيالني‬.‫الكهربية – د‬

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 Dynamic
loads circuit
design

‫ كتاب التمديدات‬: ‫المصدر‬

‫ الجيالني‬.‫الكهربية – د‬

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 Please respect the Intellectual property rights of the author.
 Do not share, reuse or redistribute this material without a clear
permission from the author.

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