HEAT TRANSFER CHARACTERISTICS OF M I N I N G CABLES
MARK A. FULLER
I E E E MEMBER
Cablec I n d u s t r i a l Cable Corporation
440 E. 8 t h S t r e e t
Marion, I n d i a n a 46952
Abstract-Power cab1es used i n m i n i ng appl i c a t i ons
a r e subjected t o a very severe p h y s i c a l environment.
I n a d d i t i o n , t h e cables a r e o f t e n expected t o be
o p e r a t i n g a t t h e i r r a t e d temperatures. Any mass o f
c a b l e i n one c o n f i n e d area such as a r e e l , w i l l re-
s u l t i n h i g h e r c a b l e temperatures a t t h a t l o c a t i o n .
The toughness o f t h e j a c k e t i s u s u a l l y compromised
a t h i g h e r temperatures and t h e heat aging approxi-
mately doubles f o r every 10 degrees C increase. The
I C E A "recomnended" d e r a t i n g f a c t o r s f o r cables on a
r e e l apply t o s h u t t l e c a r cables. These f a c t o r s are
f r e q u e n t l y ignored because t h e r e i s l i t t l e substan-
t i a t i n g data a v a i l a b l e and t h e f a c t o r s a r e q u i t e
severe. Another area o f study w i t h l i t t l e o r no
d a t a a v a i l a b l e i s f o r a c a b l e l y i n g on o r p a r t i a l l y
surrounded by s o i l . There a r e no r e l i a b l e c o r r e c t i o n
f a c t o r s a v a i l a b l e f o r t h i s t y p i c a l mining s i t u a t i o n .
L a s t l y , t h e t a b l e s t h a t a r e g e n e r a l l y used i n mining
a p p l i c a t i o n s a r e published by ICEA and apply t o a
s i n g l e i s o l a t e d c a b l e (suspended) i n a i r . The pur-
pose o f t h i s work i s t o expand, update, and p r o v i d e
new technology f o r mining cables users.
I. Introduction
Over t h e decades, many cables have been r e t u r n e d
t o t h e l a b o r a t o r y from deep mines f o r a n a l y s i s due
t o cracked and broken j a c k e t s and/or i n s u l a t i o n .
A n a l y s i s o f these cables reveals a m u l t i t u d e o f small
h a i r l i n e cracks p a r t i a1 l y through t h e j a c k e t from t h e
m i d p o i n t o f t h e c a b l e t o t h e p o i n t which i n c l u d e s t h e
i n n e r two l a y e r s on t h e r e e l . I f t h e d e r a t i n g f a c t o r s
a r e n o t s t r i c t l y adhered t o , these innermost l a y e r s
w i l l n o t have t h e heat d i s s i p a t i o n c a p a b i l i t i e s nec-
essary. This i s due t o t h e f a c t t h a t they very r a r e l y
1 eave t h e r e e l , and much o f t h e time, a r e covered by
several more l a y e r s o f cable. The I n s u l a t e d Cable
Engineers A s s o c i a t i o n (ICEA) d e r a t i n g f a c t o r s 1i s t e d
i n Appendix I , Table A serve as a general guide f o r
a l l cables [l]. They a r e more than adequate i n most
s i t u a t i o n s , such as small t r a i l i n g cables on s l a t t e d
r e e l s . How l a r g e cables r e a c t when used ( i n t h e
worst case s i t u a t i o n ) on r e e l s o f magnetic materi a1
w i t h a s o l i d drum i s one area o f study, and how a
c a b l e b u r i e d i n d r y s o i l i n a surface o r deep mine
i s t h e o t h e r area researched f o r t h i s paper.
This paper discusses t h e t a b l e recomnendations
f o r ampacity on a 4/0 AWG Type SHD-GC 8000 v o l t
cable, t h e n compares t h i s t o t h e i n d u s t r y standard
Neher-McGrath 123 c a l c u l a t i o n f o r ampacity. For
comparison, a 4/0 SHD was t e s t e d t h e r m a l l y i n t h e
1 aboratory and compared t o t h e c a l c u l a t i o n s .
11. Heat Transfer Review
The c u r r e n t - c a r r y i n g c a p a c i t y o f e l e c t r i c a l power
c a b l e i s fundamentally a heat t r a n s f e r problem.
Through conduction, convection, and r a d i a t i o n t h e
amount o f heat t h a t can be d i s s i p a t e d i n t o t h e med-
ium surrounding t h e c a b l e i s i n d i r e c t p o r p o r t i o n
t o t h e temperature and thermal c o n d u c t i v i t y o f both
t h e cable and t h e medium. The cable generates heat
by t h e c u r r e n t f l o w i n g through t h e conductors and
s h i e l d i n g system on h i g h v o l t a g e cables. Since
a l l components o f t h e cable a r e i n i n t i m a t e con-
t a c t , t h e heat generated i n t h e copper conductors
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by t h e f l o w o f c u r r e n t i s conducted t o t h e i n s u l -
a t i o n and then t o t h e j a c k e t . A t t h i s time, t h e
heat i s d i s s i p a t e d i n t o t h e a i r , water, o r s o i l i n
c o n t a c t w i t h t h e cable surface. This i s accomp-
l i s h e d through any one o f t h e t h r e e methods o f heat
t r a n s m i s s i o n l i s t e d above. Appendix I,Table B
l i s t s t h e cable m a t e r i a l s and t h e i r thermal con-
d u c t i v i t i e s C3j; Table C l i s t s t h e thermal con-
d u c t i v i t i e s f o r various surrounding mediums L 4 j .
The c a l c u l a t i o n s i n s e c t i o n I V u t i l i z e these t h e r -
mal r e s i s t i v i t y values as a s i g n i f i c a n t p a r t o f
t h e ampacity c a l c u l a t i o n .
I t was a t f i r s t thought t h a t t h e c a b l e c o u l d be
t e s t e d i n t h e dynamic s t a t e . However, equipment
and personnel l i m i t a t i o n s d i d n o t a l l o w t h i s . The
common method o f c a l c u l a t i n g t h e root-mean-square
(RMS) c u r r e n t over a machine's t y p i c a l c y c l e was
u t i l i z e d f o r a l l equations and c a l c u l a t i o n s i n
i n t h i s paper.
111. Recommended Ampacities
The recommended ampacities found i n ICEA S-68-516,
Table J 1 L21, a r e based on a s i n g l e i s o l a t e d
m i n i n g cable i n a i r and operated w i t h an open c i r -
c u i t e d s h i e l d , as would be t h e case for most TvDe SHD
-GC cables i n s u r f a c e mines. For t h e t e s t cable,
a 4/0 AWG Type SHD-GC 8000 v o l t s , Table J I shows 321
amperes a t a 40°C ambient. Using t h e ambient conver-
s i o n f a c t o r , found i n Appendix J , c a l c u l a t i o n s y i e l d -
ed 379 amperes f o r t h e t e s t cable i n a i r . I f t h i s
c a b l e were used i n a r e l a t i v e l y s h o r t l e n g t h as a
feeder c a b l e i n a deep mine s i t u a t i o n , t h i s would
be a v a l i d number. The experimental t e s t data con-
f i r m e d t h i s . A t a s u r f a c e mine, however, t h e t y p i -
c a l c a b l e l e n g t h s are 4000-5000'. Here, v o l t a q e
drop e n t e r s i n t o t h e c a l c u l a t i o n as t h e l i m i t i h g
f a c t o r . A very fundamental v o l t a g e drop ( V ) form-
u l a w i l l serve t o i l l u s t r a t e t h i s p o i n t .
IZ1 (1)
vd = 1000 d u r i n g running cond t i o n s
379(0.0623)4500
vd = 1000 = 106 v o l t s
where I = c u r r e n t
Z = impedance
1 = length
On a 4160 v o l t phase t o ground system, t h i s equals
2.5% v o l t a g e drop d u r i n g operation. I n most indus-
t r i a l a p p l i c a t i o n s , i t i s considered t h a t t h e v o l t -
age drop should n o t be g r e a t e r than 3% f o r power
c i r c u i t s . The s t a r t - u p value may be as h i g h as 6
times t h e a c t u a l o p e r a t i o n a l c u r r e n t . Therefore,
t h e 2.5% v o l t a g e drop c a l c u l a t e d above would be
g r e a t l y exceeded.
A manufacturer of m i n i n g machines p r o v i d e d a
t y p i c a l kW usage graph f o r a drag1 i n e powered by
1000' l e n g t h s o f 4/0 AWG Type SHD-GC 8000 v o l t
cable. Analysis o f t h i s curve showed a 194 amp-
e r e RMS c u r r e n t f l o w i n g i n t h e c a b l e over t h e
c y c l e t i m e and a peak demand o f 330 A. A t 330
amperes vd = 93 A (2.2%) and a t 194 Amperes
.oO 0 1989 IEEE
vd = 54 A (1.3%). From t h i s , one can see a much
g r e a t e r m a r g i n o f s a f e t y f o r t h e c a b l e and t h e on-
b o a r d e l e c t r i c a l motors and equipment t o which i t
i s s u p p l y i n g power. The 4/0 AWG SHD-GC c a b l e , a t
200 am e r e s , w i l l have a c o n d u c t o r t e m p e r a t u r e o f
P
about /2 t h e maximum recommendation o f 90°C f o r
f o r E t h y l e n e Propylene Rubber i n s u l a t e d cables.
I n deep mines, t h e s i t u a t i o n i s somewhat d i f f e r e n t
i n t h a t t h e cable lengths are shorter, so voltage
d r o p i s n o t t h e o v e r r u l i n g f a c t o r . With h i g h horse-
power, l o w v o l t a g e c o n t i n u o u s m i n i n g machines, t h e
cab1 e r e p e a t e d l y sees h i g h c u r r e n t s , perhaps even
o v e r t h e ICEA recomnended c o n t i n u o u s c u r r e n t r a t i n g
f o r a short duration. I n t h i s case, t h e r a p i d i t y
w i t h which t h e conductor can t r a n s f e r t h e h e a t t o
t h e rubber m a t e r i a l s s u r r o u n d i n g i t , d u r i n g t h e
i d l i n g p e r i o d s , m a i n t a i n s t h e i n s u l a t i o n a t normal
o p e r a t i n g temperature. I n t h e deep mine, t h e nom-
i n a l 20°C o r l o w e r ambient a i r t e m p e r a t u r e p l u s a
c o n t i n u a l 60 f e e t p e r m i n u t e minimum a i r f l o w a t
t h e working face provides b e t t e r heat t r a n s f e r than
t h e c a b l e l y i n g on t h e b o t t o m o f a p i t a t mid-day
i n t h e summertime. The s h u t t l e c a r c a b l e does n o t
r e a l i z e t h e advantage o f t h i s a i r f l o w . W i t h t h e
t y p i c a l 2 l a y e r minimum on t h e r e e l , t h e a p p r o p r i a t e
d e r a t i n g f a c t o r (Appendix I, T a b l e A) s h o u l d be used.
I n t h e n e x t s e c t i o n , mathematical comparisons have
been made f o r t h e 4/0 AWG SHD-GC a t 200 Amps, and a t
t h e maximum c o n t i n u o u s ampacity t o m a i n t a i n a 90°C
c o n d u c t o r t e m p e r a t u r e i n 20°C ambient a i r . These
c a l c u l a t i o n s t h e n have t h e s u n l i g h t , wind, and o t h e r
considerations factored i n .
p a s t have shown t h e t a b l e v a l u e s t o be c o n s e r v a t i v e .
However, as w i l l be shown i n t h e f o l l o w i n g s e c t i o n ,
t h e t a b l e s appear t o be v e r y p r e c i s e on t h e 4/0
SHD-GC t e s t e d .
Cable i n t h e p r o x i m i t y o f o t h e r e n e r g i z e d and c u r -
r e n t l o a d e d - c a b l e o r c a b l e s t o r e d on r e e l s tends t o
r a i s e t h e conductor temperature. T h i s ampacity can
be c o r r e c t e d i n one o f t h r e e ways: 1 ) by u s i n g t h e
d e r a t i n g f a c t o r s t a b l e i n Appendix I , 2) by c a l c u -
l a t i n g i n t h e a d d i t i o n a l i n t e r f e r e n c e temperature
as shown i n 122, o r 3 ) b y p h y s i c a l l y measuring t h e
e f f e c t i v e r i s e i n ambient a i r t e m p e r a t u r e f o r t h e
c a b l e s i n c l o s e p r o x i m i t y o f one a n o t h e r and e n t e r -
i n g t h i s i n t o E q u a t i o n ( 2 ) . Most mines, b o t h s u r -
f a c e and deep, s t o r e d r a g c a b l e i n c o i l s randomly
p i l e d , o r on sleds. The ambient t e m p e r a t u r e may
e a s i l y be measured i n t h i s area o f l i t t l e a i r f l o w .
T h i s w o r s t case ambient a i r t e m p e r a t u r e may t h e n be
incorporated i n t o Equation I i n p l a c e o f t h e o r i g i -
n a l 20°C ambient. I f a 30°C ambient were measured,
r e c a l c u l a t i o n would y i e l d :
(ZB)
o r a 7.3% r e d u c t i o n i n ampacity. Cables t h a t a r e
e n t i r e l y i n t h e main a i r w a y s g a i n ampacity due
t o t h e improved t h e r m a l r e s i s t i v i t y c o e f f i c i e n t
(Re) between t h e c a b l e s u r f a c e and a i r . F o r t h e
cable i n s t i l l a i r :
Re = 5.6 n ' (3)

IV. Calculations D ' s L (ATIDI s ) a25+1

.65 (1+0.0167Tm) J

The c a l c u l a t i o n ; below a r e t a k e n f r o m t h e i n d u s t r y where Re = t h e r m a l r e s i s t a n c e between

s t a n d a r d paper, The C a l c u l a t i o n o f t h e Te;perature c a b l e and a i r , t h e r m a l ohm f e e t
R i s e and Load C a p a b i l i t y o f Cable Systems, by J . H. D's = o u t s i d e d i a m e t e r o f c a b l e i n
Neher and M. H. McGrath [2]. It was f r o m t h i s paper inches
t h a t ICEA d e r i v e d many o f t h e i r ampacity t a b l e s . n ' = number o f power c o n d u c t o r s
S i n c e t h e purpose o f t h i s paper i s n o t t o d e l v e AT = t e m p e r a t u r e r i s e o f j a c k e t s u r -
d e e p l y i n m a t e r i a l s and t h e i r t h e r m a l p r o p e r t i e s , f a c e o v e r ambient, "C
t h e Neher-McGrath c a l c u l a t i o n s have been a b b r e v i a t e d . 5 = 0.9 a p p r o x i m a t i o n f o r b l a c k
The f o l l o w i n g c a l c u l a t i o n s on 4 / 0 AWG SHD-GC 8000 jackets
v o l t c a b l e i s f o r a 90°C c o n d u c t o r temperature, a Tm = mean t e m p e r a t u r e o f medium, "C
20°C ambient, and w i t h t h e c a b l e i n f r e e a i r : -
Re = 46.8
2.179 1(2.189)+(1.440)(1.969)~ = 4.275
thermal ohm f t . ( 3 A )
I= c-(Ta+ATint)
F o r t h i s same c a b l e o p e r a t i n g i n a c o n t i n u o u s
J Rdc( l + Y c ) R ' c a 4 mph a i r f l o w s i t u a t i o n ,

Re = 3.5 n '
I=
j&G&FG-
90- 20+0
= 0*342 kA
(2A)
D's ( J m + 0 . 6 2 5 ) (4)

where I =c u r r e n t i n kiloamperes where Vw = w i n d v e l o c i t y i n mph

Tc =c o n d u c t o r t e m p e r a t u r e i n "C
Ta =ambient t e m p e r a t u r e i n "C
Rdc =c o n d u c t o r r e s i s t a n c e a t Tc, ohms
Yc =l o s s e s due t o s k i n e f f e c t and
- proximity e f f e c t
R ' c a = t h e r m a l r e s i s t a n c e between
c o n d u c t o r and ambient, t h e r m a l
ohm - f e e t
A T i n t = t e m p e r a t u r e r i s e o f c a b l e due
t o extraneous h e a t source, "C
Comparing t h i s t o t h e 379 ampere t a b l e value, t h e r e
e x i s t s a 9.7% d i f f e r e n c e on t h e c o n s e r v a t i v e side.
S i n c e t h e general o p i n i o n i n t h e m i n i n g i n d u s t r y
i s t h a t t h e I C E A a m p a c i t i e s a r e 10-15% c o n s e r v a t i v e ,
t h i s i n d i c a t e s t h a t Neher-McGrath a m p a c i t i e s c o r -
r e l a t e c l o s e l y t o t h e t a b l e s as expected. A va-
r i e t y o f smaller cables t e s t e d t h e r m a l l y i n t h e
= emissivity rating o f jacket
-
Re = 10.5
2.179 L J4/2.179+0.62(0.90)] = 2.519
thermal ohm f t . ( 4 A )
T h i s a i r f l o w improves t h e h e a t t r a n s f e r by a
f a c t o r o f o v e r 1.5. S u b s t i t u t i n g 2.519 t h e r m a l
ohm f e e t f o r 4.561 as K ' c a and t h e n r e c a l c u l a t i n g
E q u a t i o n (ZA), y i e l d s 0.415 kA o r an i n c r e a s e o f
21% i n ampacity due t o t h e i n c r e a s e d a i r f l o w .
The c o e f f i c i e n t of e m i s s i v i t y ( C ) f o r t h e j a c k e t ,
0.90, i s t h e t y p i c a l v a l u e used f o r b l a c k m i n i n g
c a b l e j a c k e t s . F o r comparison, some o t h e r m a t e r -
i a l s e m i s s i v i t y c o e f f i c i e n t s are: 0.95 f o r condu-
i t s and p i p e s , 0.20 f o r b r i g h t l e a d ana aluminum,
t o .50 f o r c o r r o d e d l e a d and aluminum L2j. A

1504
black Neoprene o r Hypalon j a c k e t has a h i g h emis- The r e s u l t i s 254 amperes. This i s 30% reduction
s i v i t y c o e f f i c i e n t when compared t o t h e bkkch i n ampacity due t o a 36" deep d i r e c t b u r i a l . The
body a t u n i t y . Typical c a l c u l a t i o n s f o r colored thermal t e s t s conducted and described i n t h e next
Hypalon j a c k e t s u t i l i z e t h e s l i g h t l y lower emis- s e c t i o n show t h a t a cable b u r i e d 6" deep i n very
s i v i t y c o e f f i c i e n t o f 0.80. The black and colored d r y s o i l , and o p e r a t i n g a t t h e a e r i a l ampacity
Hypalon j a c k e t s are both compounded o f t h e same w i l l surpass t h e 90°C temperature r a t i n g .
b a s i c i n g r e d i e n t s , so t h e m a t e r i a l d e n s i t y and phys-
i c a l p r o p e r t i e s a r e approximately t h e same. The V. Laboratory Experimentation
small t h e o r e t i c a l d i f f e r e n c e i n e m i s s i v i t y due t o
c o l o r i n g i s shown i n t h e thermal r e s i s t a n c e equa- Two cables were placed under t e s t i n t h e Porta-
t i o n below as compared t o Equation(3A): b l e Cable Laboratory a t Cablec Corporation i n
-Re = 46.8
Marion, Indiana. The f i r s t , a 4/0 AWG Type SHD-
GC 8000 v o l t cable, was s e t up w i t h a p o r t i o n o f
2.179 L ( 2.189)+(1.28) (1.969) 1= i t on a s o l i d s t e e l r e e l , suspended i n a i r and l y -
i n g on t o p o f a l o n g box o f c l a y s o i l (Fig. 1 and
4.561 thermal ohm ft. (36) 4).
This obviously has o n l y a s l i g h t e f f e c t on t h e over-
a l l ampacity r a t i n g . The a c t u a l thermal s t u d i e s
i n t h e n e x t s e c t i o n show no s i g n i f i c a n t d i f f e r e n c e
i n t h e heating times, nor i n t h e o v e r a l l ampacity
f o r t h e black versus colored jacket.
Solar r a d i a t i o n f o r cables i n surface mines can
c r e a t e a great deal o f a d d i t i o n a l heat i n t h e cable.
I n d u s t r y standard c a l c u l a t i o n s i n c o r p o r a t e t h i s
r a d i a t i o n i n t o Equation ( 2 ) as an actual temperature
r i s e from an e x t e r n a l heat source. This i s c a l -
c u l a t e d f i r s t o f a l l by:

A T i n t = 7.53 D ' s Re/n' (5)

where A T i n t = temperature r i s e from e x t e r n a l
heat source i n O C
7.53 = c o e f f i c i e n t f o r black surfaces
ATint 7.53(2.179)(4.561)/3 = (5A)
24.95"C

Using Equations ( 2 ) and (5A), t h e ampacity f o r t h e

4/0 SHD-GC becomes:

-/,
I = 90 20+24 95
= 0.294 kA (2C) Fig. 1: Test Set-up

This 19% r e d u c t i o n i n ampacity due t o s o l a r rad-

i a t i o n i s s i g n i f i c a n t . Any cable t o be used i n A 0-280 v o l t output v a r i a b l e autotransformer (VAT)
surface mine a p p l i c a t i o n s w i t h a p r e d i c t e d conduc- was connected t o a heavy d u t y c u r r e n t transformer
t o r temperature o f 8O-9O0C, should i n c l u d e A T i n t as (CT) t o induce c u r r e n t i n t h e phase conductors i n
p a r t of t h e ampacity. Cable t o e a r t h conduction i s s e r i e s (Fig. 2).
f o r mining a p p l i c a t i o n s . Power cable d i r e c t b u r i a l
i s t y p i c a l l y i n 36" deep trenches w i t h f a i r l y cool
m o i s t s o i l . I n t h i s case, t h e c u r r e n t carr.ying
c a p a c i t y i s w e l l known and documented. There a r e
I C E A t a b l e s f o r cables b u r i e d 36" deep i n RHO 60,
RHO 90, and RHO 12OoC centimeters per w a t t (oC-cm/
w a t t ) s o i l s , and methods o f i n t e r p o l a t i o n L 5 l . As
an example, a 4/0 3 conductor 8000 v o l t rubber i n -
s u l a t e d cable d i r e c t l y b u r i e d has, a t 100% l o a d
f a c t o r , an ampacity o f 380 i n RHO 60 s o i l and 301
i n RHO 120 s o i l [ S I . A surface mine, i n t h e worst
case s i t u a t i o n o f summertime, may have RHO 700 s o i l
surrounding t h e cable C41. The f a c t o r which saves
t h i s cable from extreme overheating i s t h e shallow-
ness o f t h e b u r i a l . Two comnon ways t o determine
t h e r e d u c t i o n i n ampacity f o r cable due t o b u r i a l
are: 1) Equation (44), taken from L23, o r 2 ) t h e
i n t e r p o l a t i o n method above. I n both cases assump-
t i o n s must be made. To demonstrate t h e e f f e c t s o f
b u r i a l on ampacity, t h e i n t e r p o l a t i o n method was
used from [5] on a 4/0 SHD-GC 8000 v o l t cable a t
100% l o a d f a c t o r . The conversion was made from a
very damp and cool RHO 120 s o i l t o RHO 200. The
conversion f a c t o r was found t o be F=0.57. Multiply
F by t h e 50% l o a d f a c t o r , RHO 60 s o i l ampacity. Fig. 2 : CT on l e f t , VAT on r i g h t

1505

I V iiirii iiivune u i a ~ i i v r i i srules lor (ne

process-equipment connected at the
output of the pump and inform the
operator nearest to the vat that ' any
--
. .. . .. .
. .. .
The measuring c i r c u i t was comprised o f a 30-2000
ampere c u r r e n t t r a n s f o r m e r connected t o a v a r i a b l e
r e s i s t o r and t h e n t o a d i g i t a l r e a d o u t d a t a a c q u i -
s i t i on u n i t (Fig.3).
f e r e n c e between t h e l a b o r a t o r y a e r i a l c a b l e and
ICEA t a b l e s and c a l c u l a t i o n s was a 10-15 f o o t p e r
m i n u t e (fpm) average a i r f l o w ; whereas t h e ICEA
t a b l e s a r e based on f r e e a i r , w i t h no wind ~ 5 j .
C a l c u l a t i n g Re f o r t h e 4/0 SHD-GC c a b l e w i t h t h i s -
0.17 m i l e p e r hour a i r f l o w shows an i n c r e a s e i n Re
t h e r m a l ohm f e e t . Also, t h e ambient a i r t e m p e r a t u r e
i n t h e l a b o r a t o r y averaged about 25°C. The c a l c u -
l a t i o n s below show t h a t t h e a i r f l o w and t h e 5 O C
h i g h e r ambient a p p r o x i m a t e l y b a l a n c e out. F o r t h e
c a b l e r e e l , t h e thermocouple l e a d s were on t h e s i d e
o f t h e cable i n contact w i t h t h e s t e e l surface,
w h i c h negated t h e a i r f l o w e f f e c t s . Also, t h e a i r
f l o w had a n e g l i g i b l e e f f e c t upon t h e b u r i e d p o r t i o n
o f t h e cable.

Calculations f o r Laboratory Conditions

F i r s t c a l c u l a t e Re f o r 0.17 mph w i n d

Re = 10.5
2.179 C /l9+0.62(0.90)] = 5.755
t h e r m a l ohm f e e t (4fr)
R e p l a c i n g Re = 4.275 f r o m (3A) w i t h 5.755, we
f i n d t h e new R ' c a and subsequently t h e new ampac-
i t y of:
F i g . 3: Data A c q u i s i t i o n U n i t . Also, t h e Velometer = 0.314 kA (2D)
used f o r measuring a i r f l o w . 63.62(1.44)(7.734)
T h i s u n i t a l s o m o n i t o r e d and measured 30 a d d i t i o n a l Comparing t h i s t o ( 2 A ) w i t h a 25.2+1.7"C ambient
c'hannels t o which t h e Type J thermocouple l e a d s a i r temperature, which was t h e t e m p e r a t u r e range
were attached. Thermocoupl e 1o c a t i o n s i n c l u d e d b u t t h r o u g h o u t , shows t h a t t h e t h e o r e t i c a l c a l c u l a -
were n o t l i m i t e d t o : s t r a n d c e n t e r , b r a i d : h i e l d t i o n s of L 2 j balance o u t t o w i t h i n 5' of a c t u a l
s u r f a c e , and j a c k e t s u r f a c e , w i t h a s e t on t o p " l a b o r a t o r y data.
and on t h e "bottom" o f t h e c a b l e a t each o f t h e 3
p o s i t i o n s mentioned above. Through t h e s e thermo-
c o u p l e s , t h e c a b l e temperature was measured a t t h e I = 90-(25.2+0) = 0.329 kA
I C E A t a b l e ampacity, t h e machine m a n u f a c t u r e r s sug- 63.62(1.44)(6.521)
gested ampacity, and a t s e v e r a l p o i n t s in-between.
The r e s u l t s a r e shown i n T a b l e I :

TABLE I
Amperage " C e l s i u s Conductor Temperature, Hours t o S t a b i l i z e
in Air i n Soil on S o i l on Reel Ambient A i r
380 8-9 7 v6.7,o -7-- 23.5
325 76.8, 8 77.3, 10 148.0, 14 26.9
215 56.7, 6 70.9, 24 57.5, 8 110.8, 14 25.3
2 00 40.9, 6 43.3, 20 41.4, 8 71.2, 9 23.7
200 w/sun 51.7, 8 50.1, 30 53.4, 9 26.4
243 90.0, - 23.5
As shown above, t h e t a b l e ampacity i s v e r y a c c u r a t e The e q u a t i o n s below a r e computer generated b e s t
f o r t h e c a b l e i n a i r . The c a b l e d e r a t i n g t o 325 A fit curves LSee Appendix IIJ f o r h e a t i n g and c o o l -
or 15% f o r 1 l a y e r on a r e e l , i s n o t adequate on ing c h a r a c t e r i s t i c s o f 1a r g e SHD-GC cab1 es w i t h o u t
a s o l i d s t e e l drum. A l i n e a r r e g r e s s i o n a n a l y s i s sun, where y = c o n d u c t o r temperature:
between 200 and 275 Amperes i n d i c a t e d 235.6 f o r
90°C conductor t e m p e r a t u r e on t h e r e e l . T h i s i s a Heating
38% decrease due t o l a y e r i n g on t h e l a b o r a t o r y r e e l .
The a c t u a l thermal t e s t showed 243 A t o a t t a i n 90°C Amperes
o n t h e r e e l . Most mines do n o t use e n e r g i z e d c a b l e 200 y = 33.756 *EXP\0.042X) (6)
on a s o l i d s t e e l r e e l , however, some do. F o r t h e 275 y = 40.092t9.760 *LN(X) (7)
purposes o f t h i s i n i t i a l s t u d y , t h e w o r s t case S i t - 325 y = 44.299t14.428 *LN(X) (8)
u a t i o n was used due t o t h e r e a d i l y a v a i l a b l e r e e l 380 y = 46.684t25.982 *LN(X) (9)
o n t h e Tension R e e l i n g Machine i n t h e P o r t a b l e Cable
Labor a t o r y .
F o r most s u r f a c e m i n i n g , w i t h c a b l e s covered by
Cool ing

s o i l , t h e c a b l e w i l l o p e r a t e a t t h e same t e m p e r a t u r e 200-0 y = 35.448-7.139 *LN(X) (10)

as t h e c a b l e i n a i r u n t i l t h e 90°C a e r i a l ampacity i s 275-0 y = 43.145 *EXP(-O.O70X) \Ill
reached. A t t h i s p o i n t , t h e c a b l e i n s o i l r e a c t s 325-0 y = 48.654 *EXP(-0.071X) (12)
t o t h e thermal r e s i s t a n c e o f t h o r o u g h l y d r i e d s o i l . 380-0 y = 60.661 *EXP(-0.057X) (13)
D i r e c t comparisons, between c a b l e on a r e e l and on
S o i l , Were made t o t h e a e r i a l c a b l e . The o n l y d i f -

1506
 These equations d i d n o t have t h e sun f a c t o r e d i n 8kV. I t a l s o appears t h a t t h e e m i s s i v i t y c o e f f i -
because t h e l a b o r a t o r y sunlamps d i d n o t s i g n i f i - c i e n t should n o t be decreased f o r c o l o r e d Hypalon
c a n t l y a l t e r any o f t h e constants i n t h e above j a c k e t s when performing t h e o r e t i c a l c a l c u l a t i o n s .
equations .
A #2 AWG Type SHD-GC 5000 v o l t cable was a l s o l a b
Future work should i n c l u d e SHD-GC cable c u r r e n t
loaded on a s l a t t e d s t e e l r e e l f o r b e t t e r heat
t e s t e d f o r a dual comparison between black and t r a n s f e r , and on a r e e l o f non-magnetic m a t e r i a l
c o l o r e d Hypalon j a c k e t s i n s u n l i g h t and t o compare t o c u t down on induced current.
t h e heating and c o o l i n g curves t o t h e l a r g e r 4/0
SHD cable. The book ampacity o f 159 was c o r r e c t e d
f o r 20°C ambient, 159 * 1.18 = 188 Amperes. The
t e s t data t a b u l a t e d below i s f o r 180 Amperes. This
s l i g h t l y lower s e t t i n g was used due t o a problem
w i t h t h e autotransformer.

2 AWG SHD 5000 v o l t s

'Celsius Conductor TemDerature i n A i r ,

w-
Amperage ~ Hours t o Stabi1;ze
1e n t A i r
180

180w/sun 83.9, 4.5 85.7, 4.5 22.5

As t h e data shows, t h e book ampacity i s approxi-

mately 10% conservative i n t h i s case. The sunlamp
added 4-5' Celsius t o both t h e black and orange j a c k -
e t w h i l e c u r r e n t loaded, and a l s o made a consider-
a b l e d i f f e r e n c e i n t h e c o o l i n g time r e q u i r e d when t h e
power was o f f . The time/temperature data was used
f o r t h e computer generated equations below. This
demonstrates t h e d i f f e r e n c e between t h e two cables
and gives t h e best f i t curves [See Appendix 111 de-
s c r i b i n g t h e heating and c o o l i n g c h a r a c t e r i s t i c s
o f smaller SHD-GC cables; where y = conductor tem-
perature:
Heat ing
Jacket Sun
Black No y = 48.404 *EXP(O.O88X) (14)
Orange No y = 45.677 *EXP(0.103X) (15)
Black Yes y = 48.578 *EXP(O.l37X) (16)
Orange Yes y = 48.901 *EXP(O.l37X) (37) Fig. 4: 4/0 SHO-GC cable b u r i e d 6" deep i n s o i l
Cool ing
Black Yes y = 53.869 *EXP(-O.O84X) (18) References
Orange Yes y = 53.428 *EXP(-O.O93X) (19)
Black No y = 33.863 -6.895 *LN(X) (20) L11 " I n s u l a t e d $able Engineers A s s o c i a t i o n Spec-
Orange No y = 41.714 *EXP(-O.O65X) (21) if ic a t i o n , s-68-516.

VI. Concl u s i ons L21 J. H. Neher and M. H. McGrath, "The Calcula-

t i o n o f t h e Temperature Rise and Load Capa-
Cables p r o p e r l y sized f o r v o l t a g e drop and load b i l i t y o f Cable Systems," A I E E Paper No. 57-
should n o t overheat i n any o f t h e thermal environ- -
660, A p r i l 18, 1957.
ments discussed. To be sure o f t h e proper cable
s i z e , t h e worst case s i t u a t i o n f o r t h e cable must L31 Metals-Handbook -
P r o p e r t i e s and Selection,
be c a l c u l a t e d i n advance o f s e l e c t i n g t h e conductor American S o c i e t y f o r Metals, 1964, V.1,
size. Problems w i l l a r i s e i n s i t u a t i o n s where t h e 8 t h Ed.
c a b l e i s r e e l e d o r c o i l e d and allowances were n o t
made f o r t h i s i n t h e o r i g i n a l ampacity c a l c u l a t i o n . L41 I E E E Guide f o r S o i l Thermal R e s i s t i v i t y
Beware o f s t e e l r e e l s , e s p e c i a l l y those w i t h a s o l - heasurements, Published A p r i l 1979, I E t E
i d drum. Derate by more than t h e 15% recomnenda- Std P - 442, 1979.
t i o n by ICEA. I C E A 5-68-516 t a b l e J1 ampacities
a r e very p r e c i s e f o r t h e l a r g e r SHD-GC cables and c51 AIEE-IPCEA Power Cables Ampacities, Copper
10-15% conservative f o r t h e smaller cables. The Conductors Published 1962 by American I n -
cable b u r i e d i n s o i l w i l l operate 5% higher i n con- s t i t u t e o f E l e c t r i c a l Engineers.
d u c t o r temperature than t h e a e r i a l cable on t h e lower
end o f t h e t e s t s and a t l e a s t 10% h o t t e r as t h e L6 1 G. J. Conroy and H. H. H i l l , " I n t e r m i t t e n t
a e r i a l cable approaches 90'C. The cable should be Duty Ratings o f T r a i 1 ing Cabl es , "Under-
derated accordingly. The cable on t o p o f s o i l w i l l M i ne System, Proceedin-reau
ground Coal Mine Proceedings, Bureau
r u n 1-6% higher i n conductor temperature than t h e o f Mines Technology Transfer, September 16,
a e r i a l cable, depending upon c u r r e n t l e v e l s . Calcu- 1982.
l a t i o n i n d i c a t e d t h a t s u n l i g h t causes a s i g n i f i c a n t
r i s e i n conductor temperature. It appears t h a t t h e 173 John M. Mesina, "Computerized Method f o r
sun w i l l n o t have as much e f f e c t on a smaller cable, Evaluatiflg t h e S u i t a b i l i t y o f T r a i l i n g
l i k e t h e #2 SHD-GC 5kV, as on t h e l a r g e r 4/0 SHD-GC Cables, The N i n t h WVU Mining E l e c t r o t e c h -
nology Conference, J u l y 1988.

1507

lil
u i a ~ i i v r i i srules
I V iiirii i i i v ~ n e lor me
process-equipment connected at the
output of the pump and inform the
operator nearest to the vat that ' any
--
. .. . . .. .
. .. .
 C81 James J. Hansloven, " T r g i l i n g Cable S t r e s s e s
in Underground Coal Mines ," A Thesis i n M i n i n 9
En i n e e r i n P e n n s y l v a n i a S t a t e Univ., U n i -
**v e r s i t y a r k , PA, May 1978.

Appendix I

Table A
ICEA Derating Factors
No. o f L a y e r s M u l t i p l y A m p a c i t i e s By
1 0.85
. . - ~
2 0.65
3 0.45 '
4 o r more 0.35
Table a -
Thermal C o n d u c t i v i t i e s o f Various M a t e r i a l s
Copper 0.94 calorie/cm/second/degree C
A1 umi num 0.57 'I

Table C
Thermal C o n d u c t i v m f E a r t h and W a t er
Water 165 degree C l c m l w a t t
Organic S o i l
I1
Wet 400
U
Dr Y 700

Appendix I1
The computer generated e q u a t i o n s were t a k e n f r o m
best f i t curve out o f t h e f o l l o w i n g functions:
:pj' A+B *LN(X), and A *EXP(BX). The d a t a p o i n t s
we1.e e n t e r e d i n an x, y a r r a y , t i m e a g a i n s t tem-
p e r a t u r e . The computer t h e n e v a l u a t e d t h e d a t a
p o i n t s , graphed t h e t h r e e f u n c t i o n s above, and
c a l c u l a t e d t h e F index, o r t h e r a t i o o f t h e re-
g r e s s i o n mean squares t o t h e r e s i d u a l mean squares.
The e q u a t i o n s l i s t e d i n t h i s paper a r e t h o s e with
t h e h i g h e r F index. The graphs shown below a r e
f r o m computer h a r d c o p i e s o f XN, which c l o s e l y f o l -
lowed t h e graph p o i n t s and A t B *LN(X).

APPENDIX 1 1 ( c o n t ' d . )
Typical cooling Curve for Phase Conductors I n Type SHD-GC Cable
Typical Heating Curve f o r Phase Conducton i n Type SHD-GC Cable

Curve 1

Curve 2

Curve 1: X', Use f o r Rcadlng Graph Directly

Curve 1: X'. Use for Rcadtng Graph Dlrectly
Curve 2: A+PLN(X) fra Caputer M e 1 of k t u r ? Data Pofntr
Curve 2: WWX) fra W e 1 o f Actual Data Points

1so8