Chapter 7 - Equipment Sizing

EE3420E – Power Supply Systems - Printed 2021
Chapter 7
EE3420E - Power Supply Systems
Chapter 7.
Equipment sizing
Assoc. Prof. Bach Quoc Khanh, Ph.D

Electric Power Systems dept.
Hanoi University of Science and Technology
Content
1. Generality
2. Conductor sizing
3. Dimensioning of bar conductors
4. Switching device selection
5. Instrument transformer selection
Bach Quoc Khanh/EPS dept./HUST 1

Chapter 7
1. Generality
1.1. Criteria for steady-state operation
 Steady state operation (permanent): Full load current is checked. Operational
equipment’s utilization factor should be less than or equal to unit.
 Criteria:
‒ Rated voltage (insulation):
‒ Rated current (normal ratings):
 Considerations: Ambient temperature, installation.
1. Generality
1.2. Criteria for short-time operation
 Overloading:
‒ Loads in excess of normal rating. Overload operation for safety reasons or
overload for reliability requirement.
‒ Overloading capacity (permissible loading, Kol = overload current/rated current)
is a function of the overloading duration and depends on cooling conditions.
‒ In design stage, the overloading duration is assumed (for reliability
requirement) to be the mean-time to repair (MTTR).
In USSR, for transformers, Kol = 1.4 (outdoor); 1.3 (indoor) as overloading duration is less
than 5 days, 6 hours per day, initial utilization factor is less 0.93.
‒ Considerations on the co-ordination with overload protection.

Chapter 7
1. Generality
1.2. Criteria for short-time operation
 Short-circuits:
‒ Requirement for equipment stability against mechanical and thermal
stresses have to be satisfied.
‒ Criteria:
• Thermal short circuit withstand capacity (Ithz):
• Mechanical short circuit withstand capacity (Im):

Ith: Thermal equivalent short-circuit current
t k: Short-circuit duration
tthz: Rated short-circuit duration
iP: Peak short-circuit current
1. Generality
1.3. Economic optimization
 Cost function (C):
‒ Capital cost (CP).
Total Cost
‒ O&M cost (COM):

C = CP + COM
CP
COM
Optimal Size
size F (mm2); STr (kVA)

Chapter 7
2. Conductor sizing
2.1. Standards
0.5mm2 0.75 1 1.5 2.5 4
6 10 16 25 35 50
 IEC 60228: 70 95 120 150 185 240
 American wire gauge (AWG) 300 400 500 630 800 1000
AWG kcmil
1 kcmil = 0,5067 mm² Cỡ dây F (mm2) Cỡ dây F (mm2) Cỡ dây F (mm2) Cỡ dây F (mm2)
- - - - 250 127 750 380
- - - - 300 152 800 405
20 0,519 4 21,2 350 177 900 456
18 0,823 3 26,7 400 203 1000 507
16 1,31 2 33,6 450 228 1200 608
14 2,08 1 42,4 500 253 1250 633
12 3,31 1/0 53,5 550 279 1500 760
10 5,26 2/0 67,4 600 304 1750 887
8 8,37 3/0 85 650 329 2000 1010
6 13,3 4/0 107 700 355 - -
2. Conductor sizing
2.2. Current carrying capacity
 Current carrying capacity (Ampacity), Ref. IEC60050: The maximum current which
can be carried continuously by the conductor(s) (of the cable) under specified
conditions, without its steady-state temperature exceeding a specified value.
 Ampacity calculation:

Chapter 7
2. Conductor sizing
 Reference ampacity Ir for overhead line bare-conductor
qc : Convected heat loss, W/m
qr : Radiated heat loss, W/m
‒ Ref. IEEE Std. 738-1993: qs : Solar heat gain, W/m
Rac : Nominal AC resistance at
operating temperature t, /m
‒ Main factors influencing the conductor ampacity

• Ambient temperature
• Wind speed
• Solar heating
2. Conductor sizing
10

Chapter 7
2. Conductor sizing
2.2. Current carrying capacity Ambient
 For cables: Maximum temperature
Installation
temperature rise methods
IEC60364-4-52:2001 Insulation
material
Line
material
11
2. Conductor sizing
2.2. Loading capacity under normal operating condition
 Criteria for selecting the conductor size:
Iz: Current carrying capacity in real operations, A
Ir : Current carrying capacity in reference (specified) operation, A
f: Correction factor for real operations
Ib: Max. continuous current in normal operation, A (possibly
regard to n-1 reliability requirement)
Example 9.1: Sizing CADIVI’s underground 10kV 3-core cable for Ib = 120A
Ib = 120A
F (mm2) … 16 25 35 …
Iz (A) … 109 140 166 …
12

Chapter 7
2. Conductor sizing
 Correction factor f (IEC60364):
‒ On in the air or underground (f1, f2)
‒ Consider the soil thermal

resistivity (f3)
13
2. Conductor sizing
 Correction factor f (IEC60364):
‒ For groups of more than one circuit or of more than one multi-core cable (f4)
14

Chapter 7
2. Conductor sizing
 Overload protection co-ordination
Load Cable
for low voltage cable
In I2
Ib Iz 1,45Iz I
In: Nominal current of the protective device Protection

I2: The current ensuring effective operation in
the conventional time of the protective device
(1): For protection selectivity and conductor not to be overloaded.
(2): Permissible overload 45% for a conventional time.
15
2. Conductor sizing
 Overload protection co-ordination for low voltage cable
t t
t(I) fuse I2t cable
t(I) LV CB
<1g
I I
Ib In Iz I2 Ib In Iz I2 Im
 When the protective device is a circuit breaker: Only consider (1) In  Iz because I2 = 1.3ln
for CB complying with IEC 60947-2 (for industrial use) and I2 = 1,45In for CB complying with
IEC 60898 (for household and similar installations)  if In ≤ Iz, (2) will also be satisfied.
 When the protective device is a fuse : IEC60269-2-1  I2 = 1,6.In (In reality, I2 =
(1.61.9).In) (2) becomes 1.6  In ≤ 1,45  Iz or In  0.9  Iz
16

Chapter 7
2. Conductor sizing
2.3. Loading capacity under fault conditions
 Protection against thermal stress of short-circuit current
tsc, Isc The short-circuit duration (s) and effective short-circuit current (A)
F The cross-sectional area (mm2);
k Factor taking account of the resistivity, temperature coefficient and heat capacity of the
conductor material, and the appropriate initial and final temperatures.
IEC60364-4-43,
the value of k for
phase conductor
17
2. Conductor sizing
2.4. Voltage drop
 For a line segment feeding a lumped load at the end
When UA: Permissible voltage drop.
less dependent on cross-section area

0,30,4(/km) for OHL
as xo =
0,070,1(/km) for cables
18

Chapter 7
2. Conductor sizing
2.4. Voltage drop Source P1,Q1 Pn,Qn
 For a line feeder with distributed lumped loads
F1, l1 Fn, ln
‒ With the same conductor size:
‒ With the same current density:
19
2. Conductor sizing
2.5. Economical optimization
 Economic load ranges:
‒ Conductor’s annual cost function per km: ZL F1 F2 F3
IL
IL1 IL2
20

Chapter 7
2. Conductor sizing
 Kelvin’s law: Economical size of conductors
‒ Total annual cost:
Economical size: C0 Min
21
2. Conductor sizing
 Economic load density Je
‒ Economic size of conductor: C
IL : Normal load current

Je : Economic load density (pre-determined
and given in design handbooks)
F
Example 9.2:
F1 F2 Fopt F3
… 50 70 95 120 …. F(mm2)
Fopt = 75mm2
22

Chapter 7

3.1. Mechanical short-circuit strength
 Electromagnetic (electrodynamic) force between two parallel rigid conductors
‒ Electromagnetic force:
B: Flux density (T)
I: Current (A)
l: Length (mm)
‒ The force is greatest for N(3) short-circuit,

‒ Application:
• Two-phase or three-phase systems
• For rigid conductors (e.g. bar conductors, tubular conductors…)
• Post insulators (fixing with rigid conductors)
23

3.2. Busbar sizing for mechanical strength
 For parallel solid busbar conductors
‒ Each phase main conductors are single conductors.
‒ For three-phase short-circuit in 3P system,
maximum electromagnetic force on the center main
conductor:
iP2, iP3: Phase-to-phase and 3 phase
short-circuit peak currents
l: Support spacing (cm)
‒ For phase-to-phase short-circuit in 3P
d: Main busbar spacing (cm)
system or single phase system:
0: Permeability constant
(4.10-7 Vs/Am)
k: Correction factor
24

Chapter 7
3. Busbar sizing and bus supports

‒ Correction factor k:
Takes account of the
conductor spacing
and shapes.
‒ Calculate k using Dwight’s chart.
Example 9.3:
a = 5mm, b = 80mm, d = 100mm, l = 1m
 k=0,91. If iP = 35kA  Fm= 224daN Dwight’s chart
25

‒ Bending moment M on busbar
(calculated according to the laws of rigidity):
Fm: electromagnetic force (N)
l : Support spacing (cm)
‒ Bending stress on rigid busbars must be less Moment of resistance for

some conductor shapes
than permissible bending stress:
W: Moment of resistance (cm3)
V: Factor takes account of mechanical natural frequency.
IEC60865: VB = 1 (without reclosing), VB=1.8 (with reclosing)
: Factor for loading of the main conductor
per: Permissible stress of the busbar
26

Chapter 7

 For parallel attached-elements busbar conductors
‒ Each phase main busbar H is a group of t elements (sub-conductors)
‒ Dimensions:
• Main conductor spacing: a
(between two phase centers)
• Sub-conductor spacing: a12, …
• Support spacing: l
• Two adjacent sub-conductor
spacers: ls
27

‒ The electrodynamic force between the

main conductors
Parameters are similar
to the case of parallel
solid busbar conductors
‒ The electrodynamic force between
the sub-conductors
Where k1s is calculated by Dwight’s chart
28

Chapter 7

3.2. Busbar sizing for mechanical strength  and  factors

‒ Bending stress on main conductors:
‒ Bending stress on sub-conductors:
W s: Moment of resistance of sub-conductors.

Other parameters remain as for the case of solid busbar conductors.
29

3.3. Post insulator selection
 Force on post insulator
where:
: Factor depending on the type and number of supports
Vd : Factor takes account of mechanical natural frequency for supports.
For DC system: Vd = 2;
For AC single phase system: Vd  2;
For AC threee phase system: Vd  2,7
FrB: Rated force of the support insulator given by Manufacturer
30

Chapter 7

4.1. Circuit breaker (CB)
 Functions:  Operating Principle:
‒ A piece of equipment which
can make or break a circuit
either manually or by remote
control under normal
conditions, Medium voltage CB operation
‒ Break a circuit automatically

under fault condition.
‒ Make a circuit either

manually or by remote under
fault condition.
Low voltage CB operation
31

4.1. Circuit breaker
 Medium voltage circuit breaker:
‒ Standards: IEC60056; IEC60694
‒ Classifications
Arc extinction by SF6 gas
• Principles of Arc extinction: Vacuum
and SF6 (Sulphur hexafluoride) gas
• Installation: Outdoor (1), indoor (2)
(1) (2)
32

Chapter 7

Rated voltage Ur (IEC60694) The rated voltage is the maximum
4.1. Circuit breaker rms. value of the voltage that the equipment can withstand in
normal service. It is always greater than the operating voltage.
 Medium voltage circuit breaker: Rated current Ir (IEC60694): With the circuit breaker always
closed, the load current must pass through it in compliance with a
‒ Parameters maximum temperature value as a function of the materials and the
type of connections
Rated short-circuit breaking current Isc (IEC60056) The rated

short-circuit breaking current is the highest value of current that the
circuit breaker must be capable of breaking at its rated voltage
Rated peak withstand current IP (IEC60694) and making

current Ima (IEC60056): The making current is the maximum value
that a circuit breaker is capable of making and maintaining on an
installation in short-circuit. The peak value of the short-time
withstand current is equal to: 2.5Isc for 50 Hz, 2.6Isc for 60 Hz
and 2.7Isc for special applications
Rated short-time withstand current Ithr (IEC60694): the

standardised rms. value of the maximum permissible short-circuit
current on a network for the rated duration tthr of 1 or 3 seconds.
Example: Schneider’s MV circuit breaker SF1
33

‒ Ratings selection:
• Load current condition:
IL: Full load current, A

Ir: Rated normal current, A
• Rated voltage (Ue)
Us: Maximum system operating voltage, V

Ur: Rated voltage, V
34

Chapter 7

• Rated short circuit making current (Ima):.
iP: Peak short-circuit current calculated by I”k (Chapter 6)

I”k: Initial symmetrical short-circuit current
• Thermal short circuit capacity (Ithz):

Ith: Thermal equivalent short-circuit current calculated by I”k (Chapter 6)
Ithr: Rated short-circuit current - the rated short circuit duration tthr
tk : Short-circuit duration
• Rated short circuit breaking current (Isc):
35

 Low voltage circuit breaker:
Miniature circuit breaker (MCB): Molded case circuit breaker Air circuit breaker (ACB)
(MCCB)
• Ref. IEC 60898 • Ref. IEC 60947-2
• Ref. IEC 60947-2
• Typical range: 0.5A to 125A • Typical range: 630A to
• Typical range: 16A to 6300A
• Final circuit protection
1600A (3200A)
(domestic, industry) • Main incoming circuit
• Incoming circuit protection protection (mainly in
(domestic, industry) industry)
36

Chapter 7

4.1. Circuit breaker Rated Current (In): The current that the
circuit-breaker will carry continuously
under specified conditions and on which
 Low voltage circuit breaker: the time/current characteristics are based
‒ Parameters:
Rated Impulse withstand
Rated Insulation Voltage (Ui): the voltage (Uimp) for 1.2/50s
voltage on which the dielectric impulse voltage test
properties are based.
Rated Operating Voltage (Ue): System

Rated Service Short-Circuit
operating voltage
Breaking Capacity (Ics): in %
of Icu
Rated Ultimate Short-Circuit Breaking
Capacity (Icn or Icu):
Rated Short-time withstand Capacity

(Icw): assumed constant during short- Example: Schneider’s LV circuit
time delay breaker Compact NS range
37

• Load current condition: IL: Full load current, A
• Rated insulation voltage (Ui): Us: Maximum system operating voltage, V

Ui: Rated insulation voltage, V
• Rated short-circuit breaking current (Ics):
38

Chapter 7

‒ The fault-current limitation capacity: preventing the passage of the maximum prospective fault-
current, permitting only a limited amount of current to flow crossing downstream the circuit
breaker  Reduce thermal stress, mechanical stress, electromagnetic-interference effects
‒ Interrupt the short circuit energy in one half cycle or less.
39

‒ How to limit the fault-current:
Limiting isc by • High contact acceleration: Modified the fixed contact to increase the impulsion force,
increase of Ua  use double rotating contacts.
• Arc Extinction: Elongation, splitting and cooling the arc.
40

Chapter 7

4.2. Switches
 Medium voltage switch:
‒ Load break switch (LBS):
Interrupt load currents upto full
load (rated load) value. Including
a mechanism for suppression of
electric arcs. Adopts SF6 gas as
Medium voltage LBS
the medium of arc extinction.
‒ Disconnecting switch (DS):

Intended for safety isolation.
Lack a mechanism for
suppression of electric arcs, Medium voltage DS
when interrupting load current.
41

4.2. Switches
 Medium voltage switch:
‒ Switch ratings selection

iP: Peak short-circuit current calculated by I”k (Chapter 6)
Ith: Thermal equivalent short-circuit current calculated by I”k (Chapter 6)
Ithr: Rated short-circuit current - the rated short circuit duration tthr
42

Chapter 7

4.2. Switches
 Low voltage switch:
‒ Contactor: an electrically controlled switch
used for switching an electrical power circuit
‒ Functions: Interrupt power circuit upto overload

current. Not intended for short-circuit current
interruption. Thermal overload relay included.
‒ Contactor’s Ratings:
Ir : Rated normal current, A
Thermal overload relay selection:
Referred to Chapter 8
43

4.3. Fuses
 Functions: Overcurrent protection
 Medium voltage fuse (Ref. IEC60282-1)
‒ Construction:
‒ Parameters: In, I3, I2 and I1
44

Chapter 7

4.3. Fuses
 Low voltage fuse (Ref. IEC60269-1 and 2)
‒ Types:
• g (full-range breaking capacity): Overload and short-circuit
protection.
• a (partial-range breaking capacity): Short-circuit protection.
‒ Parameters:
• In
• I2
• I1
45

4.3. Fuses
 Fuse selection (ratings)
‒ Normal operation:

Ir : Rated normal current, A
‒ Breaking capacity:
I1: Maximum rated breaking current, A

Ik’’: Initial symmetrical short-circuit current, A
46

Chapter 7

4.3. Fuses
 Current-limiting fuse:
‒ Reduce the peak current (reduce mechanical
stress) and let-through energy (thermal stress)
of the protected circuit.
‒ Reduce the clearing time to less than 1/2cycle.
ip Without
CL fuse
with
CL fuse
Isc
47

4.3. Fuses
 Fuse and Switch combination: Used at sites
where circuit switching is not regular.
‒ Medium voltage applications:
• Distribution transformer protection
LBS-fuse
• Ring-main unit (RMU) combination
• Overcurrent protection combines
with load on/off switching
MV Disconnector-
‒ Low voltage applications:
fuse combination
• Motor protection
• Capacitor protection LV Switch-fuse
combination
48

Chapter 7

5.1. Voltage transformers
 Functions: Transform the primary high voltage
to secondary 100V or 110V
 Ratings selection:
‒ Insulation:
35kV outdoor VT
‒ Voltage ratio, number of secondary windings, class of

accuracy and secondary load: referred to Chapter 8
‒ 3 phase wiring diagram (Star, delta)
22kV indoor VT
49

5.2. Current transformers
 Functions: Transform the primary high current to
secondary current of 1A or 5A
 Types: Outdoor/indoor, ring-type Symbol
Indoor Outdoor Ring-type
 Parameters:
Parameter definition
50

Chapter 7

5.2. Current transformers ‒ Short-circuit withstand capacity
 Ratings selection:
‒ Normal operation:

Ith: Thermal equivalent short-circuit current
Ir : Primary rated current, A
calculated by I”k
Us: Maximum system
Ithr: Rated short-circuit current - the rated short
operating voltage, V
circuit duration tthr
‒ Voltage ratio, number of secondary iP: Peak short-circuit current calculated by I”k
windings, class of accuracy and Idyn: Maximum current for stability against
secondary load: referred to Chapter 8. mechanical stress under short-circuit current
51
52

Chapter 7 - Equipment Sizing

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EE3420E – Power Supply Systems - Printed 2021

EE3420E - Power Supply Systems

Assoc. Prof. Bach Quoc Khanh, Ph.D

Bach Quoc Khanh/EPS dept./HUST 1

 Considerations: Ambient temperature, installation.

‒ Considerations on the co-ordination with overload protection.

Bach Quoc Khanh/EPS dept./HUST 2

• Mechanical short circuit withstand capacity (Im):

‒ O&M cost (COM):

Bach Quoc Khanh/EPS dept./HUST 3

Bach Quoc Khanh/EPS dept./HUST 4

‒ Main factors influencing the conductor ampacity

Bach Quoc Khanh/EPS dept./HUST 5

Iz (A) … 109 140 166 …

Bach Quoc Khanh/EPS dept./HUST 6

‒ Consider the soil thermal

Bach Quoc Khanh/EPS dept./HUST 7

In: Nominal current of the protective device Protection

Bach Quoc Khanh/EPS dept./HUST 8

When UA: Permissible voltage drop.

less dependent on cross-section area

Bach Quoc Khanh/EPS dept./HUST 9

‒ With the same current density:

Bach Quoc Khanh/EPS dept./HUST 10

‒ Total annual cost:

Economical size: C0 Min

IL : Normal load current

Bach Quoc Khanh/EPS dept./HUST 11

3. Dimensioning of bar conductors

‒ The force is greatest for N(3) short-circuit,

3. Dimensioning of bar conductors

Bach Quoc Khanh/EPS dept./HUST 12

3. Busbar sizing and bus supports

‒ Calculate k using Dwight’s chart.

3. Busbar sizing and bus supports

‒ Bending stress on rigid busbars must be less Moment of resistance for

Bach Quoc Khanh/EPS dept./HUST 13

3. Busbar sizing and bus supports

‒ Each phase main busbar H is a group of t elements (sub-conductors)

3. Busbar sizing and bus supports

‒ The electrodynamic force between the

Where k1s is calculated by Dwight’s chart

Bach Quoc Khanh/EPS dept./HUST 14

3. Busbar sizing and bus supports

 For parallel attached-elements busbar conductors

‒ Bending stress on sub-conductors:

W s: Moment of resistance of sub-conductors.

3. Busbar sizing and bus supports

Bach Quoc Khanh/EPS dept./HUST 15

4. Switching device selection

‒ Break a circuit automatically

‒ Make a circuit either

Low voltage CB operation

4. Switching device selection

• Installation: Outdoor (1), indoor (2)

Bach Quoc Khanh/EPS dept./HUST 16

4. Switching device selection

Rated short-circuit breaking current Isc (IEC60056) The rated

Rated peak withstand current IP (IEC60694) and making

Rated short-time withstand current Ithr (IEC60694): the

4. Switching device selection

IL: Full load current, A

• Rated voltage (Ue)