Cables Sizing For Electro Chlorination Plant

PROJECT:
OWNER :
CONTRACTOR :
CONTRACTOR CONSULTANT:
OWNER'S CONSULTANT:
SYSTEM :
2 X 660 MW NCC POWER PROJECT, NELLORE DISTRICT, A.P.

NCC POWER PROJECTS LIMITED
NCC LIMITED
L&T-SARGENT & LUNDY LIMITED
TATA CONSULTING ENGINEERS LIMITED
ELECTRO CHLORINATION SYSTEM.
CABLE SIZING CALACULATION OF PMCC TO ECS TRANSFORMER INCOMER CABLE

1
2
Load Taken For Calculation
Electrolyser Transformer-1 Load 630KVA
Full load current :
KVA X 1000 / (415 X 3)

630 X 1000 / (415 X 1.732)
Amps
876.485155
Overall cable derating factor:
Group derating factor x Ambient derating factor

= 0.73 x 0.9
0.657
Uprated Currents :
FLC/ Overall cable derating factor.

876.5/0.702
Amps
1334.07177
Protection
ACB Protection
Minimum cable size for Short circuit current rating
Minimum cable size of 2.5 sq mm copper and 6.0 sq mm
For fuse protected cable
Aluminum cable are consider for 415V, 50Hz, AC 3PH
Cable selected:
3Run X 3Core 300 Sqmm. Al XLPE Cable
Current rating of 3Run X 3Core 300 Sqmm. Al XLPE Cable Amps (A)
452*3
Amps 1356
9
10
11
% of voltage drop for Running
3xIfl x L x (Rac x cos + X x sin) x 100/(Vn x 1000 x N)
a) Full Load Current in Amps (Ifl)
876.5
e) AC resistance of the cable (Ohms/km) (Rac)
0.130
b) Norminal Line Voltage in Volt (Vn)
415.0
f) Power Factor (Cos )
0.750
c) No. of cable runs (N)
3.0
g) AC reactance of the cable (Ohms/km) (X)
0.0703
d) Cable Length (L)
50.0
h) Sin
0.661
Voltage drop in %
0.87792
Voltage drop in volt

Permissible Voltage drop in % for transformer
3.64335
Conculation
3% on operation
3Run X 3Core 300 Sqmm. Al XLPE Cable satisfies all requirements
Selection of this cable is correct.
PROJECT:
OWNER :
CONTRACTOR :
OWNER'S CONSULTANT:
SYSTEM :

NCC LIMITED
CABLE SIZING CALACULATION OF PMCC TO ECP FEED PUMP MOTOR

1
2
3
Motor Load
Full load current :
55 KW
95
= 0.69 x 0.9
0.621
Uprated Currents :
Amps
152.979066
Protection
Fuse Protection
Cable selected:
3Core 185 Sqmm. Al XLPE Cable
Current rating of 3Core 185 Sqmm. Al XLPE Cable Amps (A)
329
95.0
0.212
415.0
0.860
1.0
0.0720
d) Cable Length (L)
300.0
h) Sin
0.510
Voltage drop in %
2.60561
10.81330
10
Permissible Voltage drop in % for motor
3% on operation
10
% of voltage drop for Starting
3xIst x L x (Rac x cosst + X x sin) x 100/(Vn x 1000 x N)
a) Starting Current in Amps (Ist)
570.0
0.212
415.0
f) Starting Power Factor (Cos st)
0.300
1.0
0.072
d) Cable Length (L)
300.0
h) Sin
0.954
Voltage drop in %
9.44065

39.17871
Conculation
3Core 185 Sqmm. Al XLPE Cable satisfies all requirements
Amps 329
10
11
15% on operation
PROJECT:
OWNER :
CONTRACTOR :
OWNER'S CONSULTANT:
SYSTEM :

NCC LIMITED
CABLE SIZING CALACULATION OF PMCC TO ECS STRAINER BACKWASH MOTOR

1
2
3
Motor Load
Full load current :
0.37 KW
1.1
= 0.69 x 0.9
0.621
Uprated Currents :
Amps
1.77133655
Protection
Fuse Protection
Cable selected:
3 Corex2.5 Sqmm. Cu XLPE Cable
Current rating of 3Cx2.5 Sqmm. Cu XLPE Cable Amps (A)
29
Amps 29
1.1
9.450
415.0
0.860
1.0
0.099
d) Cable Length (L)
57.0
h) Sin
0.510
Voltage drop in %
0.21399
0.88805
10
3% on operation
10
6.6
9.450
415.0
0.340
1.0
0.099
d) Cable Length (L)
57.0
h) Sin
0.940
Voltage drop in %
0.51908

2.15418
Conculation
3Core 2.5 Sqmm. Cu XLPE Cable satisfies all requirements
10
11
15% on operation
PROJECT:
OWNER :
CONTRACTOR :
OWNER'S CONSULTANT:
SYSTEM :

NCC LIMITED
CABLE SIZING CALACULATION OF PMCC TO ECS HYDROGEN DILUTION BLOWER MOTOR

1
2
3
Motor Load
Full load current :
7.5 KW
14.8
= 0.69 x 0.9
0.621
Uprated Currents :
Amps
23.8325282
Protection
Fuse Protection
Cable selected:
Current rating of 3C X 6 Sqmm. Al XLPE Cable Amps (A)
42
Amps 42
14.8
5.910
415.0
0.780
1.0
0.088
d) Cable Length (L)
55.0
h) Sin
0.626
Voltage drop in %
1.58470
6.57649
10
3% on operation
10
88.8
5.910
415.0
0.340
1.0
0.088
d) Cable Length (L)
55.0
h) Sin
0.940
Voltage drop in %
4.26394

17.69536
Conculation
3CoreX6 Sqmm. Al XLPE Cable satisfies all requirements
10
11
15% on operation
PROJECT:
OWNER :
CONTRACTOR :
OWNER'S CONSULTANT:
SYSTEM :

NCC LIMITED
CABLE SIZING CALACULATION OF PMCC TO ECS DILUTION LINE BOOSTER PUMP MOTOR
1
2
3
Motor Load
Full load current :
7.5 KW
13.4
= 0.69 x 0.9
0.621
Uprated Currents :
Amps
21.5780998
Protection
Fuse Protection
Cable selected:
42
Amps 42
13.4
5.910
415.0
0.860
1.0
0.088
d) Cable Length (L)
63.0
h) Sin
0.510
Voltage drop in %
1.80650
7.49698
10
3% on operation
10
80.4
5.910
415.0
0.340
1.0
0.088
d) Cable Length (L)
63.0
h) Sin
0.940
Voltage drop in %
4.42214

18.35187
Conculation
10
11
15% on operation
PROJECT:
OWNER :
CONTRACTOR :
OWNER'S CONSULTANT:
SYSTEM :

NCC LIMITED
CABLE SIZING CALACULATION OF PMCC TO ECS ACID CLEANING PUMP MOTOR

1
2
3
Motor Load
Full load current :
3.7 KW
6.9
= 0.69 x 0.9
0.621
Uprated Currents :
Amps
11.1111111
Protection
Fuse Protection
Cable selected:
29
Amps 29
6.9
9.450
415.0
0.860
1.0
0.099
d) Cable Length (L)
67.0
h) Sin
0.510
Voltage drop in %
1.57778
6.54777
10
3% on operation
10
41.4
9.450
415.0
0.340
1.0
0.099
d) Cable Length (L)
67.0
h) Sin
0.940
Voltage drop in %
3.82729

15.88325
Conculation
10
11
15% on operation
PROJECT:
OWNER :
CONTRACTOR :
OWNER'S CONSULTANT:
SYSTEM :

NCC LIMITED
CABLE SIZING CALACULATION OF PMCC TO ECS ALKALI TRANSFER PUMP MOTOR

1
2
3
Motor Load
Full load current :
1.5 KW
2.95
= 0.69 x 0.9
0.621
Uprated Currents :
Amps
4.75040258
Protection
Fuse Protection
Cable selected:
29
Amps 29
3.0
9.450
415.0
0.870
1.0
0.099
d) Cable Length (L)
63.0
h) Sin
0.493
Voltage drop in %
0.64148
2.66215
10
3% on operation
10
17.7
9.450
415.0
0.340
1.0
0.099
d) Cable Length (L)
63.0
h) Sin
0.940
Voltage drop in %
1.53861

6.38525
Conculation
10
11
15% on operation
PROJECT:
OWNER :
CONTRACTOR :
OWNER'S CONSULTANT:
SYSTEM :

NCC LIMITED
CABLE SIZING CALACULATION OF PMCC TO ECS NEUTRAIZATION PIT BLOWER MOTOR

1
2
3
Motor Load
Full load current :
3.7 KW
7.3
= 0.69 x 0.9
0.621
Uprated Currents :
Amps
11.75523349
Protection
Fuse Protection
Cable selected:
29
Amps 29
7.3
9.450
415.0
0.820
1.0
0.099
d) Cable Length (L)
74.0
h) Sin
0.572
Voltage drop in %
1.75980
7.30319
10
3% on operation
10
43.8
9.450
415.0
0.340
1.0
0.099
d) Cable Length (L)
74.0
h) Sin
0.940
Voltage drop in %
4.47221

18.560
Conculation
10
11
15% on operation
PROJECT:
OWNER :
CONTRACTOR :
OWNER'S CONSULTANT:
SYSTEM :

NCC LIMITED
CABLE SIZING CALACULATION OF PMCC TO ECS NEUTRAIZATION PIT TRANSFER PUMP MOTOR
1
2
3
Motor Load
Full load current :
15 KW
27.8
= 0.69 x 0.9
0.621
Uprated Currents :
Amps
44.7665056
Protection
Fuse Protection
Cable selected:
93
Amps 93
27.8
1.540
415.0
0.830
1.0
0.081
d) Cable Length (L)
75.0
h) Sin
0.558
Voltage drop in %
1.15147
4.77861
10
3% on operation
10
166.8
1.540
415.0
0.330
1.0
0.081
d) Cable Length (L)
75.0
h) Sin
0.944
Voltage drop in %
3.05156

12.66398
Conculation
10
11
15% on operation
PROJECT:
OWNER :
CONTRACTOR :
OWNER'S CONSULTANT:
SYSTEM :

NCC LIMITED
CABLE SIZING CALACULATION OF PMCC TO ECS CW SYSTEM HYPO DOSING PUMP MOTOR
1
2
3
Motor Load
Full load current :
22 KW
40
= 0.69 x 0.9
0.621
Uprated Currents :
Amps
64.4122383
Protection
Fuse Protection
Cable selected:
93
Amps 93
40.0
1.540
415.0
0.840
1.0
0.0808
d) Cable Length (L)
57.0
h) Sin
0.543
Voltage drop in %
1.27265
5.28150
10
3% on operation
10
240.0
1.540
415.0
0.330
1.0
0.0808
d) Cable Length (L)
57.0
h) Sin
0.944
Voltage drop in %
3.33696

13.84838
Conculation
10
11
15% on operation
PROJECT:
OWNER :
CONTRACTOR :
OWNER'S CONSULTANT:
SYSTEM :

NCC LIMITED
CABLE SIZING CALACULATION OF PMCC TO ECS SWI SYSTEM HYPO DOSING PUMP MOTOR
1
2
3
Motor Load
Full load current :
11 KW
19
= 0.69 x 0.9
0.621
Uprated Currents :
Amps
30.5958132
Protection
Fuse Protection
Cable selected:
54
Amps 54
19.0
3.950
415.0
0.900
1.0
0.084
d) Cable Length (L)
55.0
h) Sin
0.436
Voltage drop in %
1.56641
6.50061
10
3% on operation
10
114.0
3.950
415.0
0.330
1.0
0.084
d) Cable Length (L)
55.0
h) Sin
0.944
Voltage drop in %
3.61847

15.01665
Conculation
10
11
15% on operation
PROJECT:
OWNER :
CONTRACTOR :
OWNER'S CONSULTANT:
SYSTEM :

NCC LIMITED
CABLE SIZING CALACULATION OF PMCC TO ECS RW SYSTEM HYPO DOSING PUMP MOTOR
1
2
3
Motor Load
Full load current :
2.2 KW
4.6
= 0.69 x 0.9
0.621
Uprated Currents :
Amps
7.40740741
Protection
Fuse Protection
Cable selected:
29
Amps 29
4.6
9.450
415.0
0.810
1.0
0.099
d) Cable Length (L)
54.0
h) Sin
0.586
Voltage drop in %
0.79956
3.31816
10
3% on operation
10
27.6
9.450
415.0
0.340
1.0
0.099
d) Cable Length (L)
54.0
h) Sin
0.940
Voltage drop in %
2.05645

8.53428
Conculation
10
11
15% on operation
IEC DWG NO
NTPC_DRG_NO
PROJECT
CUSTOMER
NAME OF VENDOR
SYSTEM
IEC-W1309-060
0260-139-PVE-U-002
VALLUR THERMAL POWER PROJECT
NTPC TAMIL NADU ENERGY COMPANY LIMITED,CHENNAI
IEC FABCHEM LIMITED, Chennai.
CABLE SIZING CALACULATION OF MAIN CABLES FOR ELECTRO CHLORINATION PLANT
1 Load Taken For Calculation

2 Full load current :
Process Load 230kW + Owners Load 40kW(50kVA) = 270kW
kW x 1000/(3 x V x cos x Efficiency)

270 X 1000/(1.732 X 415 X 0.85(PF) X 0.95(Efficiency)
Amps 465.2
3 Overall cable derating factor:

= 0.79 x 0.9
0.71
4 Uprated Currents :
465.2/0.71
Amps 655
5 Protection
Fuse Protection
6 Minimum cable size for Short circuit current rating


and Earthed Neutral system.
7 Cable selected:
4R X Single Core 630sqmm. Al. Ar. FRLS. XLPE Cable
8 Current rating of Single Core 630sqmm. Al. Ar. FRLS. XLPE Cable
As per IS:
814A
9 % of voltage drop for Running current of 460.9A
3xIrx L x (Rac x cos + X x sin) x 100/(V x 1000)

3 x 465.2 x 50(0.065 x 0.85 + 0.075 x 0.017) x 100\(415 x 1000)
of 50 meter length cable :
% 0.5487190935
10 Permissible Voltage drop in %
2.5% on running operation
11 % of voltage drop for Starting current :
% of Voltage drop of Running current x 3.5 times
0.55 x 3.5
% 1.925
12 Permissible Voltage drop
10% at starting
13 Conculation
4R X Single Core 630sqmm. Al. Ar. FRLS. XLPE Cable satisfies all requirements

Cables Sizing For Electro Chlorination Plant

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Cables Sizing For Electro Chlorination Plant

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PROJECT:

2 X 660 MW NCC POWER PROJECT, NELLORE DISTRICT, A.P.

CABLE SIZING CALACULATION OF PMCC TO ECS TRANSFORMER INCOMER CABLE

Load Taken For Calculation

Electrolyser Transformer-1 Load 630KVA

Full load current :

KVA X 1000 / (415 X 3)

Overall cable derating factor:

Group derating factor x Ambient derating factor

FLC/ Overall cable derating factor.

Minimum cable size for Short circuit current rating

Minimum cable size of 2.5 sq mm copper and 6.0 sq mm

For fuse protected cable

Aluminum cable are consider for 415V, 50Hz, AC 3PH

3Run X 3Core 300 Sqmm. Al XLPE Cable

% of voltage drop for Running

3xIfl x L x (Rac x cos + X x sin) x 100/(Vn x 1000 x N)

a) Full Load Current in Amps (Ifl)

e) AC resistance of the cable (Ohms/km) (Rac)

b) Norminal Line Voltage in Volt (Vn)

f) Power Factor (Cos )

c) No. of cable runs (N)

g) AC reactance of the cable (Ohms/km) (X)

d) Cable Length (L)

Voltage drop in volt

2 X 660 MW NCC POWER PROJECT, NELLORE DISTRICT, A.P.

CABLE SIZING CALACULATION OF PMCC TO ECP FEED PUMP MOTOR

FLC/ Overall cable derating factor.

Minimum cable size for Short circuit current rating

Minimum cable size of 2.5 sq mm copper and 6.0 sq mm

For fuse protected cable

Aluminum cable are consider for 415V, 50Hz, AC 3PH

3Core 185 Sqmm. Al XLPE Cable

Current rating of 3Core 185 Sqmm. Al XLPE Cable Amps (A)

% of voltage drop for Running

3xIfl x L x (Rac x cos + X x sin) x 100/(Vn x 1000 x N)

a) Full Load Current in Amps (Ifl)

e) AC resistance of the cable (Ohms/km) (Rac)

b) Norminal Line Voltage in Volt (Vn)

f) Power Factor (Cos )

c) No. of cable runs (N)

g) AC reactance of the cable (Ohms/km) (X)

d) Cable Length (L)

Voltage drop in volt

Permissible Voltage drop in % for motor

% of voltage drop for Starting

3xIst x L x (Rac x cosst + X x sin) x 100/(Vn x 1000 x N)

a) Starting Current in Amps (Ist)

e) AC resistance of the cable (Ohms/km) (Rac)

b) Norminal Line Voltage in Volt (Vn)

f) Starting Power Factor (Cos st)

c) No. of cable runs (N)

g) AC reactance of the cable (Ohms/km) (X)

d) Cable Length (L)

Voltage drop in volt

3Core 185 Sqmm. Al XLPE Cable satisfies all requirements

Selection of this cable is correct.

2 X 660 MW NCC POWER PROJECT, NELLORE DISTRICT, A.P.

CABLE SIZING CALACULATION OF PMCC TO ECS STRAINER BACKWASH MOTOR

FLC/ Overall cable derating factor.

Minimum cable size for Short circuit current rating

Minimum cable size of 2.5 sq mm copper and 6.0 sq mm