PowerX Engineering Training

Present

How to Calculate, Size and Select

LT Cables

Main Office:
Commercial Bank Plaza, Level 14, West Bay, Doha, QATAR. P.O Box 27111.

email Us: training@po-x.com

Call Now : +974- 44528046, 74455244, 30358817

www.po-x.com,
training@po-x.com

We build future Engineers 1

Purpose

How to Calculate, Size and Select

LT Cables

In this book, you will completely understand how to select and size

your cables for any installation. The explanations have been made
very simple for better understanding, It includes different
examples on cable calculation, sizing and selection and others.
In this complete cable guide, a step by step approached was used
which will be best methods for your understanding.

So enjoy it.
We build future Engineers 2
Welcome LT Cable Size

We build future Engineers 3

We build future Engineers 4
 Cable Sizing – Overview
Cable sizing is a very important step in electrical
engineering. Since all electrical equipment would not
function without a conductor running between the
source and the load, cables make up a significant
portion in electrical engineering.

We build future Engineers 5

 In actual EPC projects, cable qty (based on
percentage of total BOQ items) make up about 20-
40%+ of total electrical cost.

We build future Engineers 6

Although the amount of cables depend on the scope
and size of the plant, cable sizing still remains a
crucial aspect in electrical engineering.

NOT only does it govern the cost of electrical

system, it also governs the safety of the entire
electrical system.

We build future Engineers 7

 Consequences Of Wrong
Cable In Your Industrial Application
- THE EQUIPMENT MAY NOT BE
POWERED PROPERLY
(INSUFFICIENT VOLTAGE).

- THE CABLE COULD

OVERHEAT, CAUSING
INSULATION TO FAIL/PARTIAL
DISCHARGE AND FIRE TO
OCCUR.

- AS A RESULT OF THE ABOVE,

A WHOLE SECTION OF CABLE
TRAY / TRENCH COULD BURN-
OUT.

We build future Engineers 8

This guide examines the sizing of electrical cables (i.e. cross-sectional area) and its
implementation in various international standards. Cable sizing methods do differ
across international standards (e.g. IEC, NEC, BS, etc.) and some standards emphasize
certain things over others. However the general principles underlying any cable sizing
calculation do not change. In this article, a general methodology for sizing cables is
first presented and then the specific international standards are introduced.

We build future Engineers 9

 International Standards
• IEC
• IEC 60364-5-52 (2009)
(http://webstore.iec.ch/webs
tore/webstore.nsf/standards/
IEC%2060364-5- 52!
opendocument) "Electrical
installations in buildings - Part
5-52: Selection and erection
of electrical equipment -
Wiring systems" is the IEC
standard governing cable
sizing.
We build future Engineers
• NEC
• NFPA 70 (2011)
(http://www.nfpa.org/aboutt
hecodes/AboutTheCodes.asp
?
DocNum=70&cookie_test=1)
"National Electricity Code" is
the equivalent standard for
IEC 60364 in North America
and includes a section
covering cable sizing in Article
300.
10
 International Standards
•BS
•BS 7671 (2008)
(http://electrical.theiet.org/
wiring-regulations/indexic)
"Requirements for Electrical
Installations - IEE Wiring
Regulations" is the
equivalent standard for IEC
60364 in the United
Kingdom.
We build future Engineers
•AS/NZS
•AS/NZS 3008.1 (2009)
(http://infostore.saiglobal.com/sto
re/Details.aspx?
productid=1141542) "Electrical
installations - Selection of cables -
Cables for alternating voltages up
to and including 0.6/1 kV" is the
standard governing low voltage
cable sizing in Australia and New
Zealand. AS/NZS 3008.1.1 is for
Australian conditions and AS/NZS
3008.1.2 is for New Zealand
conditions.
11
We build future Engineers 12
 Cable Conductor
As per IEC 60502

The cable conductor can

be:
- Copper
- Aluminum

Selection of any of these

depends on client, with a
notable in price for
aluminum, but with less
ampacity rating compared
to copper.

We build future Engineers 13

 Cable – Construction Overview
BEFORE WE DELVE INTO THE PROCESS OF CABLE SIZING, LET’S TAKE
A LOOK AT A TYPICAL CABLE CONSTRUCTION

We build future Engineers 14

Cable – Construction Overview
IT IS TYPICALLY A
NON-METALLIC SEMI-
CONDUCTING
SCREEN BEFORE
INSULATION,
PROVIDED FOR
ELECTRICAL
SHIELDING IF
SPECIFIED BY THE
CLIENT.

We build future Engineers 15

Actual CABLE - Overview

We build future Engineers 16

 Cable Construction

The basic characteristics of the cable's physical construction

includes:

• Conductor material - normally copper or aluminum.

• Conductor shape - e.g. circular or shaped.
• Conductor type - e.g. stranded or solid.
• Conductor surface coating - e.g. plain (no coating), tinned,
silver or nickel
• Insulation type - e.g. PVC, XLPE, EPR.
• Number of cores - single core or multicore (e.g. 2C, 3C or
4C).
We build future Engineers 17
 Cable Insulation
As per IEC 60502

THERMOPLASTIC:
-PVC
THERMOSETTING:
-XLPE
-EPR
-HEPR

TYPICAL INSULATION IS EITHER PVC OR XLPE.

We build future Engineers 18

THE CONDUCTOR SCREEN IS:

-NON-METALLIC, SEMI CONDUCTING IN

COMBINATION WITH A METALLIC LAYER.
-SEMI-CONDUCTING TAPE

IT IS TYPICALLY USED IN MV CABLES AT THE

REQUEST OF CLIENT, WHERE COPPER TAPE
SCREEN (CTS) IS USED FOR EARTH FAULT
CURRENT PATH.

We build future Engineers 19

CABLE SIZING – CONSTRUCTION
FILLER

SPACE BETWEEN THE CORES ARE FILLED WITH

NON-HYGROSCOPIC FILLER (WHICH IS USUALLY
A SOFT POLYMER, LIKE PVC), ALSO ON THE
OUTSIDE OF THE INSULATED CONDUCTORS.
THIS KEEPS THE CABLE CORES IN-PLACE AND
RETAINS THE CIRCULAR SHAPE OF THE CABLE.

We build future Engineers 20

CABLE SIZING – CONSTRUCTION
ARMOUR

Cable armours can be:

- Galvanized steel flat wire or round wire
- Aluminium or aluminium alloy for single-core cables
- Double tape steel, galvanized steel, aluminium or
aluminum alloy

Armour is provided for mechanical protection of cable.

it is also provided as requested by client, and usually
for underground/trench layed cables.
As per IEC 60502

We build future Engineers 21

CABLE SIZING – CONSTRUCTION
OUTER SHEATH

- NORMALLY BLACK (OTHERWISE RED OR

ORANGE)
LV CABLES ARE USUALLY BLACK, WHILE
MV CABLES ARE RED
- PVC OR POLYETHYLENE (THERMOPLASTIC)
- CHEMICAL ADDITIVES FOR CABLE
PROTECTION

We build future Engineers 22

 CABLE BENDING

If an insulated cable is bent too sharply, the

insulation and sheath on the inside of the bend
will be compressed, whilst that on the outside
will be stretched, This can result in damage to
the cable.
The bending factor must be used to assess the
minimum acceptable bending radius. Values
for common cables, both the tension and
compression must be fully considered.
We build future Engineers 23
We build future Engineers 24
 Why do the calculation?
 Operate continuously
under full load without
being damaged.
 Withstand the worst
short circuits currents
flowing through the
cable.
We build future Engineers
 Provide the load with a
suitable voltage (and
avoid excessive voltage
drops).
 (optional) Ensure
operation of protective
devices during an
earth fault.
25
 Cable Sizing Conditions

How the cable will be installed ?

• Above ground or underground
Installation / arrangement - e.g. for underground cables, is it
directly buried or buried in conduit? for above ground cables,
is it installed on cable tray / ladder, against a wall, in air, etc.
• Cable bunching, i.e. the number of cables that are bunched
together
• Cable spacing, i.e. whether cables are installed touching or
spaced
• Soil thermal resistivity (for underground cables)
• Depth of laying (for underground cables)
• For single core three-phase cables, are the cables installed in
trefoil or laid flat. We build future Engineers 26
Cable Construction

Any QUESTIONS ?

We build future Engineers 27

SIZING FOR CABLES IS DONE IN 4 AREAS:

1. Continuous current 3. Cable voltage drop

carrying capacity of the should be less than
cable. defined voltage drop.

2. Derating Factor :No. of 4. Cable short circuit

cable runs ≥ (Full load capacity should be higher
current / Cable derating than system short circuit
current). capacity at that point.

We build future Engineers 28

Cable Sizing – Step 1

We build future Engineers 29

 Current Carrying Capacity Overview
Consideration for continuous current carrying
capacity is mainly based on vendor catalogues,
listing various ampere ratings, for various sizes
of cables.

The ampere rating listed in a vendor catalogue

considers certain environment and installation
conditions.

We build future Engineers 30

Those conditions that affect the ampacity of
cables are:

-Thermal resistivity of soil (if buried)

-Depth of laying (if buried)
-Ambient temperature (above/under
ground)
-Laying of conductors

The conditions stated by vendor for those

conditions need to be noted, because these
will affect the derating factors.
We build future Engineers 31
Cable Sizing – Step 2

We build future Engineers 32

We build future Engineers 33
 Cable size – Step 3
Cable sizing based on voltage drop deals with the resistance &
reactance of the cable (data given by vendor), and also the
distance of the cable.
In theory, the longer the distance, the larger the voltage drop.
And for low voltage, this becomes increasingly important, which
is why low voltage cables often end up with multiple runs of
cables.

We build future Engineers 34

 Cable size

We build future Engineers 35

 CURRENT DERATING – DEPTH OF LAYING

For depth of
laying, typical
table of correction
factors is:

We build future Engineers 36

Hence the ampere rating of the catalogue shall be
multiplied by this derating factor to obtain the
derated rating of the cable, which is used for sizing
the cable.

For example, for 3c x 50 mm2 cable, if df is 0.6, and

the rating as per catalogue is 192a, then the actual
maximum rating to consider is:
192a x 0.6 = 115 a

We build future Engineers 37

Ambient temperature is considered for both
underground and above ground cables.
Typical correction factor for ambient
temperature are:

We build future Engineers 38

 Cable Grouping
Cable grouping is based on planned/actual laying conditions. Proximity and
quantity of cables affect the rating of the cables, as indicated in a typical
grouping table as follows:

We build future Engineers 39

Note:
That cable grouping factors are usually common either
for above-ground installation / underground installation.
This factor is more closely related to proximity of cables
than location/temperature.

Few things to consider as well:

- MV cables typically has space of 2d center-to-center.
- LV cables typically are always touching
- Worst case touching case is typically taken for standard
of cable sizing.

We build future Engineers 40

Cable Sizing – Step 4

We build future Engineers 41

 Short circuit Overview
Maximum short circuit is based on the ka rating of the
connected switchgear/mcc bus.
Initial temperature is typically chosen from maximum
operating temperature of the cable.

While the final temperature is typically chosen from

the limiting temperature of the insulation.

We build future Engineers 42

 Short Circuit Calculations
For the short circuit duration, in theory this would be based on
the short circuit withstand time of the switchgear/MCC bus as
well. although it is safe to size it this way, this will cause the
minimum cable size to be oversized un-realistically.
Therefore, t here is commonly considered to be the tripping time
of the breaker/fuse connected to the cable.
For mv (VCB/ACB), this is roughly 0.25 seconds.
For LV MCB/fuse, this is roughly .1 ms or .001 seconds
(sometimes less).
To get an more realistic figure, we would have to consult with the
vendor breaker catalogue for the actual or standard tripping time
of the protective device.
We build future Engineers 43
 Ok, let’s dive into calculations...

Example # 1
Electrical load of 80KW, distance between source and system
voltage 415V three phase, power factor is 0.8, permissible
voltage drop is 5%, demand factor is 1.

Cable laying detail:

Cable is directly buried in ground in trench at the depth of 1
meter. Ground temperature is approximate 35 Deg. Number of
cable per trench is 1. Number of run of cable is 1 run.

Soil details:
Thermal resistivity of soil is not known. Nature of soil is damp soil.

QA- What is the appropriate Cable size ?

We build future Engineers 44
 Solution
Firstly: Consumed Load = Total Load x Demand Factor:
Consumed Load in KW = 80 · 1 = 80 KW.

Secondly: We have to convert Electrical load 80KW into KVA

Apparent power (kVA) x power factor (pf) = actual power (kW)
kVA x Pf = kW
Therefore, kVA = kW/p.f [making kVA subject of the formula]

Consumed Load in KVA = KW/P.F

= 80/0.8 = 100 KVA

Thirdly: What is the Full Load Current required

I = P/ V x 1.732 x p.f
[P= 100kVA = 100 x 1000], V= 415, p.f = 0.8

Full Load Current = (100 x 1000) / (415 x 1.732 x 0.8) = 174.8 [175Amp]
We build future Engineers 45
Now select the cable base on current rating of 175A
from [Table 1 in page 53]:

Cable 95mm2

We build future Engineers 46

 Example # 2
For electrical wiring installation in a building,
Total load is 4.5kW and total length of cable
from energy meter to sub circuit distribution
board is 35 feet. Supply voltage is 220V and
temperature is 40°C (104°F).

QA - Find the most suitable size of cable from

energy meter to sub circuit if wiring is installed
in conduits ?

We build future Engineers 47

 Solution
Total Load = 4.5kW = 4.5 x1000W = 4500W
20% additional load = 4500 x (20/100) = 900W

Total Load = 4500W + 900W = 5400W

Total Current = I = P/V = 5400W /220V =24.5A
[single phase]

• Now select the size of cable for load current of

24.5A (from Table 1) page 53. 10mm2

Current rating for 40°C (104°F) = 28 x 0.94 = 26.32 Amp.

We build future Engineers 48

 Example # 3
What is the size of cable suits for this given
situation ?

Load = 5.8kW
Volts = 230V
Length of Circuit = 35meter
Temperature = 35°C (95°F)

We build future Engineers 49

 Solution
Load = 5.8kW = 5800W
Voltage = 230V
Current = I = P/V = 5800 / 230 = 25.2A
20% additional load current = (20/100) x 5.2A = 5A [safe
factor]

Total Load Current = 25.2A + 5A = 30.2A

Now select the size of cable for load current of 30.2A (from
Table 1).

Answer: 10mm2 cable size

We build future Engineers 50

 Example 4
Following Loads are connected in a building:-
Sub-Circuit 1
• 2 lamps each of 1000W and
• 4 fans each of 80W
• 2 TV each of 120W

Sub-Circuit 2
• 6 Lamps each of 80W and
• 5 sockets each of 100W
• 4 lamps each of 800W

If supply voltages are 230V then Calculate circuit current and Cable
size for each Sub- Circuit?
We build future Engineers 51
 Solution
Total load of Sub-Circuit 1
= (2 x 1000) + (4 x 80) + (2×120)
= 2000W + 320W + 240W = 2560W
Current for Sub-Circuit 1 = I = P/V = 2560/230 = 11.1A

Total load of Sub-Circuit 2

= (6 x 80) + (5 x 100) + (4 x 800)

= 480W + 500W + 3200W= 4180W
Current for Sub-Circuit 2 = I = P/V = 4180/230 = 18.1A

Therefore, Cable suggested for sub circuit 1 = (13Amp) 4mm2

Cable suggested for Sub-Circuit 2 = (22.6Amp) [25% safe factor] 6mm2

Total Current drawn by both Sub-Circuits = 11.1A + 22.6A = 33.7amp

So cable suggested for Main-Circuit = (34Amp) 10mm2

We build future Engineers 52

We build future Engineers 53
We build future Engineers 54
Cable calculation
Software

We build future Engineers 55

Cable Sizing – Any QUESTIONS

We build future Engineers 56

We build future Engineers 57