Chapter 8

Power Cables
Design
 Chapter 8 [POWER CABLES DESIGN]

8.1. Introduction
The following types of power cable are mainly used for distribution
purposes in the low-voltage (LV) range:
Ø PVC insulated cables.
Ø Cross-linked polyethylene (XLPE) cables
For LV distribution purposes, the choice is basically between XLPE cables and
PVC-insulated cables. The XLPE cables have higher current ratings than PVC
cables for the same conductor size. Normally XLPE cables tend to be slightly
more expensive than PVC cables.
The choice between these two types for LV applications will normally be
determined by economic considerations (the relative prices at that stage)
and availability. Bear in mind that a slightly smaller XLPE cables can chosen
for the same current requirement, which have other spin-offs, for example
space-saving on cable racks or in trenches, slightly reduced labor costs for
insulation.

8.2. PVC insulated cables

Low voltage copper conductor PVC cables are extensively used for domestic
home appliances wiring, house wiring and
internal wiring for lighting circuits in
factories, power supply for office
automation, in control, instrumentation,
submarine, mining, ship wiring
applications etc. due to its high tensile
strength, superior conductivity, better
flexibility and ease of jointing.
Ø Note on PVC insulation
For PVC insulation continuous
conductor temperatures up to 70 °C are permissible. Care must be
exercised in matching the cable to the circuit protection. Under short-
circuit conditions, a maximum conductor temperature of 160 °C is
allowed for a maximum period of 1 s.

Advantages of PVC Cables:

Ø A non-hygroscopic insulation almost unaffected by moisture.

Ø Non-migration of compound permitting vertical installation.
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Ø Complete protection against most forms of electrolytic and chemical

corrosion.
Ø A tough and resilient sheath with excellent fire - resisting qualities.
Ø Good ageing characteristics.
Not affected by vibration.

8.3. Cross-linked polyethylene (XLPE) cables

XLPE used as conductor insulating materials in these
cables. XLPE is a semiconductor, and provide partial
insulation as well as electrical stress relieving. The
conductors, with their XLPE layers, are embedded in PVC
to provide total insulation. Steel wires are used for
mechanical strength, and may also be used to provide the
return path (or part thereof) for earth fault currents. The
outer sheath is normally a PVC sheath, to provide
insulation and waterproofing.

Ø Note on XLPE insulation

For XLPE insulation, continuous conductor
temperatures up to 90 °C are permissible with excursions of up to 130
°C for a maximum of 8 h con nuous per event, with a maximum total
of 125 h per annum.

Advantages of XLPE Cables:

Ø Higher Current Rating.

Ø Higher Short Circuit Rating.
Ø Longer Service Life.
Ø For a short me it can withstand maximum 130 ̊ C and is favorable to
endure short circuit stresses.
Ø Because of the thermosetting process taking place due the effect of
cross linking, the crack resistance is increased.
Ø The thermal resistivity of cross-linked material is favorably low,
compared to thermoplastic material.
Ø The low dielectric loss is a significant advantage.
Ø The excellent mechanical features of the insulation improve the
protection against external effects.
Ø The resistance of the XLPE to acids, alkalis is outstanding and is often
compensating the adverse environmental influences.

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Comparison between XLPE & PVC insulation material:

Ø To choose the right insulating material, for a specific application, one

should know the difference between each insulating material and the
other. The following table shows the difference between XLPE and
PVC properties.

PVC XLPE
Maximum sustained conductor temperature 70oC 90oC
Ground temperature 25oC 25oC
Ambient air temperature(free air shaded) 30oC 30oC
Ground thermal resistivity 1.2Km/W 1.2Km/W
Depth of laying to top of cable or duct 500mm 500mm

Current rating parameters

8.4. Selection of cable size

When selecting a cable for your specific application, a number of variables
require attention. These are:
Ø Application
Ø Size and type of load to be supplied
Ø Permissible voltage drop
Ø Prospective fault current
Ø Circuit protection
Ø Installation conditions

8.4.1. Application
As we mentioned before that For LV distribution purposes, the choice is
basically between XLPE cables and PVC-insulated cables. The XLPE cables
have higher current ratings than PVC cables for the same conductor size.
Normally XLPE cables tend to be slightly more expensive than PVC cables.
In our design we chose the PVC cables.

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8.4.2. Size and type of load to be supplied

In order to select the appropriate cable, it is necessary to know the voltage
and the load current, as the first step in the selection process.
×
The following formulae apply: Ifl =
√ × ×
Icable = Ifl ×1.2

Use this value of current to determine the cable size by reference to the
relevant manufacturer’s tables for copper conductors.

8.4.3. Permissible voltage drop

A slightly larger conductor size may be chosen for safety aspects, and to
provide for the higher than usual current, which may be experienced during
starting of electric motors.
Measure voltage drop at cable during motor starting and insure that voltage
drop percentage (voltage drop/phase voltage) not exceed 5%

8.4.4. Prospective fault current

Cable insulation must bears fault current, we must measure fault current (by
using ETAP program in Short Circuit Calculation Chapter) and insure that the
value of short circuit current pass in the cable less than cable short circuit
×
current withstand that get by this formula: ISC =
√
Where:
K=115 for PVC/copper cables of 1000 V ra ng
K=143 for XLPE/copper cables of 1000 V rating
K=76 for PVC/aluminum (solid or stranded) cables of 1000 V ra ng
K=92 for XLPE/aluminum (solid or stranded) cables of 1000 V ra ng
And where:
A=the conductor cross-sectional area in mm2
t=the duration of the fault in seconds

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8.5. Our design of cables

Floor Panel Panel C.S.A Branch circuit c.s.a

feeder cables
(A)
1 28.254 4-core P.V.C (4 mm2) All loads of panel 1 1-core2.5 mm2
All loads of panel 2 1-core2.5 mm2
Ground 2 30.41 4-core P.V.C (6 mm2) All loads of panel 3 1-core2.5 mm2
(G42:G46 & FCU) 3*1-core2.5 mm2
3 130.95 4-core P.V.C (70 mm2)

1 66.78 4-core P.V.C (25 mm2) All loads of panel 1 1-core 2.5 mm2
Mezzanine (M26:M28) 1-core 4 mm2
2 42.18 4-core P.V.C (10 mm2) FCU 3*1-core 2.5 mm2
All loads of panel 2 3*1-core 4mm2
1 49.64 4-core P.V.C (16 mm2) All loads of panel 1 1-core 2.5 mm2
Service (S27 & FCU) 3*1-core 2.5 mm2
2 88.88 4-core P.V.C (35 mm2) All loads of panel 2 3*1-core 6 mm2

1 73.63 4-core P.V.C (25 mm2) lighting of panel 1 1-core 2.5 mm2
Equipment of panel 1 1-core 4 mm2
Recrea onal 1 2 159.23 4-core P.V.C (95 mm2) All loads of panel 2 3*1-core 4mm2
(R1_46:R1_56) 1-core 4 mm2
3 88.4 4-core P.V.C (35 mm2) (R1_53:R1_55) 3*1-core 4mm2

1 45.9 4-core P.V.C (10 mm2) All loads of panel 1 1-core 2.5 mm2
Recrea onal 2 All loads of panel 2 1-core 2.5 mm2
2 67.9 4-core P.V.C (25 mm2) (R2_47&R2_50) 3*1-core 2.5mm2

1 54.12 4-core P.V.C (16 mm2) All loads of panel 1 1-core 2.5 mm2
Bed rooms All loads of panel 2 1-core 2.5 mm2
2 31.96 4-core P.V.C (6 mm2) (B42&FCU) 3*1-core 2.5mm2

1 55.68 4-core P.V.C (16 mm2) All loads of panel 1 1-core 2.5 mm2
Apartment All loads of panel 2 1-core 2.5 mm2
2 23.23 4-core P.V.C (4 mm2) (A28 &FCU) 3*1-core 2.5mm2

1 318.08 4-core P.V.C (300 mm2) RF1: RF4 3*1-core 25mm2

Roof floor RF5 3*1-core 4mm2
2 225.19 4-core P.V.C (185 mm2) RF7 1-core 2.5 mm2
RF10: RF13 3*1-core 25mm2
CAR PARK 1 19.91 4-core P.V.C (4 mm2) C1:C4 1-core 2.5 mm2
(C5&FCU) 3*1-core 2.5mm2

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Pump room
Pump Type feeder C.S.A
Boost pump 214.5 2*4-core P.V.C (150 mm2)
Heat Water pump 257.4 4-core P.V.C (240 mm2)
Fire pump 214.5 2*4-core P.V.C (150 mm2)
Water treatment pump 8.58 4-core P.V.C (2.5 mm2)

Chiller loads
Chiller (No.1) 285.99 3*4-core P.V.C (240 mm2)
Chiller (No.2) 285.99 3*4-core P.V.C (240 mm2)
Chiller (No.3) 285.99 3*4-core P.V.C (240 mm2)
Chiller (No.4) 285.99 3*4-core P.V.C (240 mm2)
Note that C.S.A means Cross section area

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