Eepl - Apgenco - 128 - Pd - e - Cal - 1029_r5

8/11/2019 Eepl - Apgenco - 128 - Pd - e - Cal - 1029_r5

1/20

PROJECT:

KAKATIYATHERMAL POWER PROJECT, STAGE-1UNIT # 1 (1 X 500 MW)

OWNER:

ANDHRA PRADESH POWER GENERATION CORPORATIONLIMITED LIMITED

HYDERABAD, ANDHRA PRADESH

CONSULTANT:

DESEINCONSULTING ENGINEERSNEW DELHI - INDIA

CONTRACTOR:

ENERGO ENGINEERING PROJECTS LIMITED

LT POWER CABLE SIZING CALCULATION

PROJECT DOC. TITLE : LT POWER CABLE SIZING CALCULATION

CONTRACTOR DOC. NO : EEPL - APGENCO - 128 - PD - E - CAL - 1029 Revision: 5

APPROVALSTATUS : APPROVAL

REV DATE

INITIALS SIGN INITIALS SIGN INITIALS SIGN

DETAILS OF REVISION

PREPARED CHECKED APPROVED

0 31/01/14 KM KM KKB INITIAL SUBMISSION

1 19/02/14 KS KM KKBREVISED AS PER COMPLIANCE

REPORT

2 21.04.14 KM KM KKB REVISED AS PER COMMENTS



5 28.06.14 KM KM KKB LEGIBLE PRINT ENCLOSED


2/20


3/20

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z AA AB AC

co s ( r ) sin ( r) co s ( s ) sin ( s)

1 415V MCC HP W ater Pump Motor-1Slurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 DOL(SFU) 90 90 415 0.94 0.860 0.510 0.3 0.95 154.8889 1115.2 0.7 221.2698 3C X 150 249 0.2640 0.072 2 0.76732 3.091373 180

2 415V MCCSpace HeaterforHP waterPump

Motor-1

Slurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 MCB 90 0.06 240 - 0.730 0.683 - - 0.25 - 0.7 0.357143 3C X 4 34 9.4800 0.0927 1 0.130945 - 90

3 415V MCC HP W ater Pump Motor-2Slurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 DOL(SFU) 88 90 415 0.94 0.860 0.510 0.3 0.95 154.8889 1115.2 0.7 221.2698 3C X 150 249 0.2640 0.072 2 0.750268 3 .022676 176


Motor-2

Slurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 MCB 88 0.06 240 0.76 0.730 0.683 - - 0.25 - 0.7 0.357143 3C X 4 34 9.4800 0.0927 1 0.128036 - 88

5 415V MCC HP Water Pump Motor-3Slurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 DOL(SFU) 88 90 415 0.94 0.860 0.510 0.3 0.95 154.8889 1115.2 0.7 221.2698 3C X 150 249 0.2640 0.072 2 0.750268 3 .022676 176


Motor-3

Slurry WaterPump

House

XLPE,FRLS,


7 415V MCC Drain Pump Motor-1Slurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 DOL(SFU) 60 9.3 415 0.85 0.800 0.600 0.3 0.95 19.02734 1 36.9968 0.7 27.18191 3C X 10 59 3.9400 0.0837 1 1.525739 4 .327669 60

8 415V MCC Drain Pump Motor-2Slurry WaterPump

House

XLPE,FRLS,


9 415V MCC Ash Slurry Pump Motor-1Slurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 DOL(ACB) 75 160 415 0.95 0.850 0.527 0.3 0.95 275.6649 1 984.787 0.7 393.807 3C X 300 367 0.1300 0.071 2 0.638095 3 .306669 150

10 415V MCCSpace HeaterforAsh Slurry Pump

Motor-1

Slurry WaterPump

House

XLPE,FRLS,



House

XLPE,FRLS,



Motor-2

Slurry WaterPump

House

XLPE,FRLS,


1 3 415V MCC Ash Slurry Pump Motor-3Slurry WaterPump

House

XLPE,FRLS,



Motor-3

Slurry WaterPump

House

XLPE,FRLS,


1 5 415V MCC Ash Slurry Pump Motor-4Slurry WaterPump

House

XLPE,FRLS,



Motor-4

Slurry WaterPump

House

XLPE,FRLS,



House

XLPE,FRLS,



Motor-5

Slurry WaterPump

House

XLPE,FRLS,



House

XLPE,FRLS,

ArmouredAluminium Air 1 DOL(ACB) 65 160 415 0.95 0.850 0.527 0.3 0.95 275.6649 1 984.787 0.7 393.807 3C X 300 367 0.1300 0.071 2 0.553016 2.86578 130


Motor-6

Slurry WaterPump

House

XLPE,FRLS,


21 415V MCC Seal Water Pump Motor-1Slurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 DOL(SFU) 90 11 415 0.85 0.800 0.600 0.3 0.95 22.50545 1 62.0393 0.7 32.15065 3C X 10 57 3.9400 0.0837 1 2.706956 7 .678122 90

22 415V MCC Seal Water Pump Motor-2Slurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 DOL(SFU) 90 11 415 0.85 0.800 0.600 0.3 0.95 22.50545 1 62.0393 0.7 32.15065 3C X 10 57 3.9400 0.0837 1 2.706956 7 .678122 90

23 415V MCC EOT Crane PanelSlurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 SFU 60 5.8 415 0.85 0.800 0.600 0.3 0.95 11.86651 8 5.43889 0.7 16.95216 3.5C X 25 95 1.5400 0.08 1 0.380351 1 .151036 60

24 415V MCC LIGHTING TRANSFORMER MCC RoomXLPE,FRLS,

ArmouredAluminium Air 1 MCCB 35 16 415 0.92 0.840 0.543 0.3 0.95 28.80427 207.3907 0.7 41.14896 3.5C X 25 95 1.5400 0.08 1 0.562546 - 35

2 5 4 15 VMC C VE NT F AN C ON TR OL C AB IN ET- 1Slurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 SFU 65 7.5 415 0.85 0.800 0.600 0.3 0.95 15.34463 1 10.4813 0.7 21.9209 3C X 10 59 3.9400 0.0837 1 1.332971 3 .780893 65

26VENTFANCONTROL

CABINET-1Exhaust Fan-1

Slurry WaterPump

House

XLPE,FRLS,


27VENTFANCONTROL


Slurry WaterPump

House

XLPE,FRLS,


Max.

current

rating of

cable per

run

Resistance of

selected cable

(Ohm/km)

Reactanc

e of

selected

cable

(Ohm/km)

From To

Starting

Starting

CurrentLoc at io n C ab le Typ e C on du ct or

Full Load

CurrentCable lay

Qty. of

motor/

feeder

Type of

Feeder

Unit

Distance

(m)

Voltage

Drop at

starting

Total cable

lengthLoad (kW)Voltage (V) Efficiency

Running

Derating

Factor

Derated

Current

Size of

Cable

selected

based on

current

Number

of Runs

%Voltage

Drop at

running

S. No.

EEPL LT POWER CABLE SIZING CALCULATION

Project No.

Doc. No.

Revision No.

Consultant

CLIENT : APGENCO

128

EEPL-APGENCO-128-PD-E-CAL-1029

5

DESEIN

PROJECT NAME: WFAHS FOR AUGMENTATION SYSTEM FOR KAKATIYA TPP STAGE-I Date 28/06/14


4/20

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z AA AB AC

co s ( r ) sin ( r) co s ( s ) sin ( s)

Max.

current

rating of

cable per

run

Resistance of

selected cable

(Ohm/km)

Reactanc

e of

selected

cable

(Ohm/km)

From To

Starting

Starting

CurrentLoc at io n C ab le Typ e C on du ct or

Full Load

CurrentCable lay

Qty. of

motor/

feeder

Type of

Feeder

Unit

Distance

(m)

Voltage

Drop at

starting

Total cable

lengthLoad (kW)Voltage (V) Efficiency

Running

Derating

Factor

Derated

Current

Size of

Cable

selected

based on

current

Number

of Runs

%Voltage

Drop at

running

S. No.

EEPL LT POWER CABLE SIZING CALCULATION

Project No.

Doc. No.

Revision No.

Consultant

CLIENT : APGENCO

128

EEPL-APGENCO-128-PD-E-CAL-1029

5

DESEIN

PROJECT NAME: WFAHS FOR AUGMENTATION SYSTEM FOR KAKATIYA TPP STAGE-I Date 28/06/14

28VENTFANCONTROL


Slurry WaterPump

House

XLPE,FRLS,


29VENTFANCONTROL


Slurry WaterPump

House

XLPE,FRLS,


30VENTFANCONTROL


Slurry WaterPump

House

XLPE,FRLS,


31 415V MCC VENT FAN CONTR OL CABIN ET-2 MCC R oom XLPE,FRLS,Armoured

Aluminium Air 1 SFU 25 4.4 415 0.85 0.800 0.600 0.3 0.95 9.002182 6 4.81571 0.7 12.86026 3C X 10 59 3.9400 0.0837 1 0.300773 0 .853125 25

32VENTFANCONTROL

CABINET-2Supply Fan-1 MCC Room

XLPE,FRLS,


33VENTFANCONTROL

CABINET-2Supply Fan-2 MCC Room

XLPE,FRLS,


34VENTFANCONTROL

CABINET-2Exhaust Fan-1 MCC Room

XLPE,FRLS,


35VENTFANCONTROL

CABINET-2Exhaust Fan-2 MCC Room

XLPE,FRLS,

ArmouredAluminium Air 1 DOL(SFU) 30 1.1 415 0.76 0.730 0.683 0.3 0.95 2.758419 1 9.86062 0.7 3.940599 3C X 4 31 9.4800 0.0927 1 0.241196 0.7291 30

36 415V MCC UPSExisting Ash Handling

Control Room

XLPE,FRLS,

ArmouredAluminium Air 3 SFU 165 4 415 0.85 0.800 0.600 0.3 0.95 8.183802 58.92337 0.7 11.69115 3C X 10 59 3.9400 0.0837 1 1.804638 - 165

37 415V MCC MOTORISED PLUG VALVE MCC RoomXLPE,FRLS,

ArmouredAluminium Air 1 RDOL(SFU) 90 2.2 415 0.85 0.800 0.600 0.3 0.95 4.501091 3 2.40785 0.7 6.43013 3C X 4 34 9.4800 0.0927 1 1.291611 3 .569161 90





40 415V MCCMOTORISEDVALVE FROM CT

BLOW DOWNMCC Room

XLPE,FRLS,


41 415V MCCMOTORISEDVALVE FOR MAKE

UPWATERMCC Room

XLPE,FRLS,


42 415V MCC WELDING R ECEPTACLE-1Slurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 SFU 35 18 415 0.92 0.840 0.543 0.3 0.95 32.4048 233.3146 0.7 46.29258 3.5C X 25 95 1.5400 0.08 1 0.632865 - 35

43WELDING

RECEPTACLE-1WELDING RECEPTACLE-2

Slurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 - 35 18 415 0.92 0.840 0.543 0.3 0.95 32.4048 233.3146 0.7 46.29258 3.5C X 25 95 1.5400 0.08 1 0.632865 - 35

44 415V MCC WELDING RECEPTACLE-3 MCC RoomXLPE,FRLS,

ArmouredAluminium Air 1 SFU 90 18 415 0.92 0.840 0.543 0.3 0.95 32.4048 233.3146 0.7 46.29258 3.5C X 25 95 1.5400 0.08 1 1.627366 - 90

45WELDING

RECEPTACLE-3W EL DI NG R EC EP TA CL E- 4 M CC Ro om

XLPE,FRLS,

ArmouredAluminium Air 1 - 90 18 415 0.92 0.840 0.543 0.3 0.95 32.4048 233.3146 0.7 46.29258 3.5C X 25 95 1.5400 0.08 1 1.627366 - 90

46 415V MCC Space H eater Bus DuctSlurry WaterPump

House

XLPE,FRLS,


47 415V MCCMarshalling Boxfor Service

Transformer

Slurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 MCB 20 1 240 0.76 0.730 0.683 - - 4.17 - 0.7 5.952381 3C X 4 34 9.4800 0.0927 1 0.484983 - 20

48 MLDB Lighting Panel-1 MCC RoomXLPE,FRLS,

ArmouredAluminium Air 1 SFU 50 5 415 0.85 0.800 0.600 - - 10.22975 - 0.7 14.61393 3 .5C X 25 95 1.5400 0.08 1 0.27324 - 50

49 MLDB Lighting Panel-2Slurry WaterPump

House

XLPE,FRLS,

ArmouredAluminium Air 1 SFU 55 5 415 0.85 0.800 0.600 - - 10.22975 - 0.7 14.61393 3 .5C X 25 95 1.5400 0.08 1 0.300564 - 55

1 ALLLT POWER CABLESHALL BE 1100 VGRADE, SINGLE/MULTI CORE, STRANDED AL CONDUCTOR, XLPEINSULATED WITHPVCINNER SHEATHANDOUTER SHEATHMADEOFFRLSPVC COMPOUND.THE ARMOURING SHALLBE AL/GALVANISED STEEL ROUNDWIRE.

2

3

NOTE:-

CABLE SIZES HAVE BEEN CALCULATED AS PER THE AVAILABLE KW RATING.SIZING MAYBE REVISED FOR ANY REVISIONIN KW RATING.

THE LENGTHS OF CABLES HAVE BEEN CALCULATED BASED ON MECHANICAL GA DRAWINGS. HOWEVER FOR ANYVARIATIONTHE SAME SHALL BE TAKEN CARE BYEEPL.


5/20

1

ANNEXURE-A

1.0 DESIGN BASIS FOR LT POWER CABLES

1.1.0 Sizing criteria:

Power cables will be sized to satisfy the following Criteria:

Short circuit withstand capacity for applicable fault current and duration. Full load current carrying capacity under installation conditions. Voltage drop during running and starting conditions Derating factors due to higher ambient temperatures, grouping of cables

/method of installation

1.2 Full load current rating

Power Cables shall be sized to carry the required load current at site conditions. As thecurrent ratings specified in the Standards and Cable Catalogues are at Design ambienttemperature of 40 C in open isolated installations, cable current rating at actual sitecondition need to be estimated by applying suitable rating factors for site ambienttemperature & site installation (grouping) conditions based on manufacturersrecommendation.

Required cable current rating = Full load current / (Ambient temperature rating factor xGroup rating factor)

a) Ambient temperature rating factor

As per Cable Catalogue enclosed as Annexure-D, recommended ambient correction

factors are as follows:

Ambient Air Temperature Correction Factor

40C 1.050C 0.9Ground Temperature Correction Factor

30C 1.0

40C 0.91

b) Group rating factor

Group rating factors for laying conditions are considered as follows as per cablemanufacturer's catalogue:(Cuts from catalogue is enclosed as Annexure-D)


6/20

2

Conditions of laying Rating factor

Multicore Cables

LT Cables below 120sq.mm laid on cable trays exposed toair, the cables touching and trays in tiers by 300 mm. 0.66

For 6 trays with 9 cables per tray.LT Cables below 120sq.mm laid inside concrete trench withremovable covers on cable trays where air circulation is

0.60restricted, the cables touching and trays in tiers by 300mm.

3 trays with 9 cables per tray.LT Cables 120sq.mm. & above laid on cable trays exposedto air, the cables separated by one cable dia. and trays in

0.86tiers by 300 mm.

For 6 trays with 9 cables per tray.LT Cables 120sq.mm. & above laid inside concrete trenchwith removable covers on cable trays where air circulation isrestricted, the cables separated by one cable dia. in tiers by

0.78300mm.

3 trays with 9 cables per tray.

LT Cables laid direct in ground in horizontal formation

0.69

(Depth of laying 750mm and with 150mm spacing betweenthe cables)

For 4 cables in group with 150mm spacing

Single core Cables

LT Cables in trefoil formation separated by 2 cable dia, laidinside concrete trench with removable covers on cable trayswhere air circulation is restricted

For 3 trays with 3 trefoils per tray

0.81

LT Cables laid on cable trays exposed to air, the cables intrefoil formation separated by 2 cable dia, and trays in tiers by300 mmFor 6 trays with 3 trefoil per tray

0.90

LT Cables laid direct in ground in horizontal formation (Depthof laying 750mm and with 150mm spacing between thetrefoils)For 2 trefoils in group with 150mm spacing

0.81

c) Net derating Factor (Cables not buried in ground)

Net Derating factor : Temperature rating factor x Rating factor for layingconditions


7/20

3

For multicore cables below 120 sq.mm : 0.9 x 0.60 = 0.54For multicore cables 120 sq.mm & above : 0.9 x 0.78 = 0.702

For single cables : 0.9 x 0.81 = 0.729

1.3 Short circuit rating criteria

415V System fault level is considered as 50kA for 1 sec as specified in the tender

specification.

Cables will be sized for the following short circuit rating .

Cables from 415 V MCC to Motors (Breakeroperated)

50 kA for 0.16 sec

Feeders 415V MCCB/Fuse Protected Fuse cut-off current for 10

m.sec

Note: The short circuit withstand duration indicated above is based on the protection

relayoperation time, lock out relay operation time and the breaker tripping time for thebreaker controlled feeders. For Fuse/MCCB protected feeders, the fault clearing timeof the Fuse/MCCB has been considered. Discrimination has been shown among theabove feeders so that the Upstream breakers shall not trip for the faults at downstreamfeeders.

1.4 Voltage drop limitation criteria

To maintain voltage at motor terminals / equipment end within desirable limit asspecified in the tender specification, it is proposed to limit the voltage drop in the cables

within the following limits:

Feeder Steady state Voltage drop

(full load / running

condition)

Voltage dip (During Motor

Starting)

415V Sup[ply Feeder 3%-

415V Motor Feeder 3% 15%


8/20

4

Following formulae have been used for voltage drop calculations:

3 Phase AC Motors 3xIrxL/1000x(R cos1+X sin1) x100 %Voltage Drop during running condition = --------------------------------------------------

(V x No. of runs / phase)

3xIsxL/1000x(R cos2+ X sin2) x100% Voltage Drop during starting condition = --------------------------------------------------


3 Phase AC Feeders

3xIrxL/1000x(R cos1+X sin1) x100

% Voltage Drop during running condition = --------------------------------------------------(V x No. of runs / phase)

1 Phase AC Feeders

2xIrxL/1000x(R cos1+X sin1) x100% Voltage Drop during running condition = --------------------------------------------------


DC Feeders2xIrxL/1000xR x100

% Voltage Drop during running condition = -----------------------------

(V x No. of runs)

Where,Ir is rated full load current in AmpsV is rated voltage in VoltsL Feeder length in MetreR is cable resistance in ohms / kmX is cable reactance in ohms / km

Cos1 is running power factorIs is starting current in amps

Cos2 is starting power factor


9/20

5

2.0.0 LT CABLE SIZING SAMPLE CALCULATIONS

2.1 Sample Cable Sizing Calculation for 415V AC Motor Feeders

2.1.1 Input Data

Motor Rating (P) : 160 kW

Rated Voltage (V) : 415V

Efficiency (K1) : 0.95

Power Factor (cos1) : 0.85Sin1 : 0.527

Starting PF (cos2) : 0.3Sin2 : 0.95Breaker rating : 630A

Short Circuit Rating (If) : 50 kA

Fault Clearing time (tf) : 0.16 sec

2.1.2 Minimum size required for short circuit withstand capacity

Ish= 50 kAt = 0.16 seconds

K = 0.094Substituting the values,

Minimum size required for Short circuit withstand capacity (A1) : 50 x(0.16) / 0.094

: 212.8 sq.mm

Say : 240 sq.mm

2.1.3 Minimum size required for full load current rating

Full load Current (Ir) : P / (3 x V x K1 x cos1): (160 x 1000) / (3 x 415 x 0.95 x 0.85)


10/20

6

: 275.66 Amps

Required Cable Current (Ic1) : Ir / (d1)Where,

d1 is deration factor for Ambient temp & Grouping, which is 0.702 for XLPE multicore

Cables above 120 sq.mm.

Required Cable Current (Ic1) : 275.66 / (0.7 )

: 393.80 Amps

For a minimum size of 3CX300 sq.mm, current rating is 367 Amps.

2.1.4 Voltage drop Calculation

%Volt Drop during running condition = 3 x Ir x L/1000 x (R cos1+ X sin1) / V x 100

%Volt Drop during starting = 3 x Is x L/1000 x (R cos2+ X sin2) / V x 100

Resistance of 3Cx300 sq.mm XLPE Cable (Rc) : 0.13 ohms /km

Reactance of 3Cx300 sq.mm XLPE Cable (Xc) : 0.071 ohms /km

% Voltage drop in running condition ( Vr) for 100 M length Cable is

= 3 x Ir x L /1000 x (Rc cos1+ Xc sin1)/ Runs XV x 100= 3 x 275.66 x 50/1000 x (0.13 x 0.85 + 0.07 X 0.527)/ 2X 415 x 100= 0.42 %

% Voltage drop during starting condition (Vs) for 100 M length Cable is

= 3 x Is x L / 1000 x (Rc cos2+ Xc sin2)/ V x 100

= 3 x 7.2 x 275.66 x 50/1000 x (0.13 x 0.3 + 0.0881 X 0.954)/ 415 x 100= 2.2 %

Calculated % voltage drop during running condition is less than the permissible drop of

3%.

Calculated % voltage drop during starting is less than the permissible drop of 15%..


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Documents

Eepl - Apgenco - 128 - Pd - e - Cal - 1029_r5