Principles of Cable Sizing

Angelo Baggini, angelo.baggini@unibg.it, Bergamo University - Engineering Department

Via Marconi 5, 24044 Dalmine (BG) – Italy
Introduction

Cable sizing vs Cable selection

Cable
the process
sizing isofthe Cable sizing is the
the process of
selecting
process ofappropriate
selecting process of selecting
selecting the
appropriate
sizes for electrical
sizes for appropriate sizes for
appropriate type of
electrical
power power
cablecable electrical power cable
cable
conductors.
conductors conductors.
Process of cable sizing

1. Gather data about the cable, its installation conditions, the load that
it will carry

2. Determine the minimum cable size based on current rating

(continuous current carrying capacity) SA

3. Determine the minimum cable size based on voltage drop SB

4. Determine the minimum cable size based on inrush current SC

5. Determine the minimum cable size based on short circuit

temperature rise SD

6. Select the cable based on the largest of the sizes calculated in

the steps above S = MAX(SA, SB, SC, SD)
1. Data gathering

Basic cable data

Load data

Cable installation
1. Data gathering
LOAD DATA

Number of phases
three phase or single phase

Voltage
Rated voltage, allowed voltage drops

Full load current (A) or power (kW or kVA)

Full load power factor (pu)

Length of line
from source to load - this length should be as close as possible to the actual
route of the cable and include enough contingency for vertical drops / rises and
termination of the cable tails
1. Data gathering
BASIC CABLE DATA

• Conductor material
Cu or Al

• Insulation or cable type

PVC, XLPE, EPR (IEC cables),
TW, THHW, XHH, etc. (NEC cables)

• Number of cores
1X, 2X, 3X … or 3G, 4G …
1. Data gathering
CABLE INSTALLATION

Installation method
cable tray / ladder, in conduit / raceways, on a wall, in air, directly
buried, etc
Ambient or soil temperature at the installation site

Cable grouping
number of other cables bunched together or installed in the same area

Cable spacing
whether cables are installed touching or spaced

Soil thermal resistivity

(for underground cables)

Trefoil or laid flat

(for single core three-phase cables)
1. Data gathering

Load
I=50 A, 400 V 3 phase H OW ?
Installation
In air perforated cable trays
T=40 °C
L=100 m

Grouping
2 cable trays – 4 cables

Voltage drop
steady-state 2%
inrush 10%

Cable Type
3 conductors – EPR
2. Current rating (SA)

DATA:
• installation method
• cable type
• load sustained current (Ib)

Selection from the Standards of the:

• base current rating (Io)

• correction factors:
• k1 for variation in ambient temperature
• k2 for adjacent circuits
• k3 for variation in burial depth
• k4 for ground thermal resistance

The maximum sustained current rating (Iz):

Iz (S) >= Io · k1 · k2 · k3 · k4 >= Ib

 2. Current rating (SA)
Thermal phenomena

HV and MV cables
WH Y ?

JOULE LOSSES
INTO THE
CONDUCTOR
EDDY
CURRENTS INTO DIELECTRIC
THE SCREEN OR LOSSES INTO THE
ARMOUR* INSULATION**

* Screened or armoured single core cables only

** HEPR > 10 kV only or PVC > 10 kV only
2. Current rating (SA)
Thermal phenomena

LV cables
WH Y ?

JOULE LOSSES
INTO THE
CONDUCTOR
2. Current rating (SA)
Thermal phoenomena

Heat is
WH Y ?

Tramsmitted to the Gathered into the

environment by conductor increasing
conduction and temperature
convention
2. Current rating (SA)
Thermal phoenomena

Heat is
WH Y ?

Tramsmitted to the Gathered into the

environment by conductor increasing
conduction and temperature
convention
2. Current rating (SA)
Thermal phoenomena

Heat is
WH Y ?

Tramsmitted to the Gathered into the

environment by conductor increasing
conduction and temperature
convention
2. Current rating (SA) > Thermal phenomena
Accumulated heat

The amount of heat accumulated in the conductor depends on

the thermal capacity

Thermal capacity is function of:

• Specific heat capacity of the material ( c )

• cCu = 3,45 x 106 J/K m3
• cAl = 2,50 x 106 J/K m3

• Volume (conductor section)

2. Current rating (SA) > Thermal phenomena
Transferred heat

The quantity of transferred heat depends on:

• heat transfer modes (convection, conduction)

• thermal resistance of the "circuit"
2. Current rating (SA) > Thermal phenomena
Transferred heat > Thermal resistance

Thermal resistance is a function of:

• thermal resistivity Heat flow ENVIRONMENT

• geometry of the problem

Thermal
resistance
mean 2

Thermal
resistance
mean 1
2. Current rating (SA) > Thermal phenomena
Transferred heat > Thermal resistance

Thermal insulating effect of electrical insulation and cable sheaths shall

be calculated by using construction data and thermal resistivities.

For single-core cables with a metal sheath for example:

Tk=T1+T2= (Q1/2π) ln(d1/dL)+ (Q3/2π) ln(d3/dM)

d1 d3
dM dL
2. Current rating (SA) > Thermal phenomena
Transferred Heat > Transfer modes

Heat transmission modes from the surface to the environment

• transmission by conduction (underground cables)

GROUND

• transmission by convection (air cables)

AIR
2. Current rating (SA) > Thermal phenomena
Steady-state conditions

In dynamic equilibrium inside the conductor

heat accumulation such as to dispose to the outside ( ambient ) all the heat
developed within the cable

GENERATED
HEAT CONDUCTOR TEMP.

ENVIRONMENT TEMPERATURE
2. Current rating (SA) > Thermal phenomena
Steady-state conditions

GENERATED
HEAT

CONDUCTOR TEMP.

ENVIRONMENT TEMPERATURE
2. Current rating (SA) > Thermal phenomena
Steady-state conditions

GENERATED
HEAT

CONDUCTOR TEMP.

ENVIRONMENT TEMPERATURE
2. Current rating (SA) > Thermal phenomena
Steady-state conditions

when ΔT of the cable compared

GENERATED
to the environment is totally
HEAT
dispelled, cables temperature
remains constant

CONDUCTOR TEMP.

ENVIRONMENT TEMPERATURE
2. Current rating (SA) > Thermal phenomena

• Rating calculation therefore involves the solution of a heat

problem

θlim − θa
Iz =
nR( Rϑc + Rϑa + Rϑx )

• current-carrying capacity is a characteristic of a cable :

• of a certain type
• of a certain section
• in a certain installation
2. Current rating (SA) > Thermal phenomena

Ground Temperature
Air Temperature
Climate (1m depht)
Min(°C) Max(°C) Min(°C) Max(°C)
Tropical 25 55 25 40
Sub-Tropical 10 40 15 30
Temperate 0 25 10 20

-cable capacity should be calculated for maximum temperature

-if required , minimum values ​will be used for winter capacity
2. Current rating (SA)

Load
I=50 A, 400 V 3 phase H OW ?
Installation
In air perforated cable trays
T=40 °C
L=100 m

Grouping
2 cable trays – 4 cables

Voltage drop
steady-state 2%
inrush 10%

Cable Type
3 conductors – EPR
2. Current rating (SA)
Equivalent load current

H OW ?
𝐼𝐼𝑏𝑏
𝐼𝐼𝐼𝐼 ≥
(k1 · k2 · k3 · k4 )

• k1 for variation in ambient temperature

• k2 for adjacent circuits
• k3 for variation in burial depth
• K4 for ground thermal resistance
2. Current rating (SA)
Equivalent load current - K1

H OW ?

Insulation- Temperature (°C)

Installation
type
25 30 35 40 45

In air perforated cable trays

in air 1.06 1.00 0.94 0.87 0.79

2 cable trays – 4 cables

PVC
bounded 0.95 0.89 0.84 0.77 0.71
mobile 1.08 1.00 0.91 0.82 -
EPR
in air 1.04 1.00 0.96 0.91 0.87

L=100 m
T=40 °C
gound 0.96 0.93 0.89 0.85 0.8
2. Current rating (SA)
Equivalent load current - K1

H OW ?

Insulation- Temperature (°C)

Installation
type
25 30 35 40 45

In air perforated cable trays

in air 1.06 1.00 0.94 0.87 0.79

2 cable trays – 4 cables

PVC
bounded 0.95 0.89 0.84 0.77 0.71
mobile 1.08 1.00 0.91 0.82 -
EPR
in air 1.04 1.00 0.96 0.91 0.87

L=100 m
T=40 °C
gound 0.96 0.93 0.89 0.85 0.8
2. Current rating (SA)
Equivalent load current - K2

H OW ?

In air perforated cable trays

T=40 °C
L=100 m
2 cable trays – 4 cables

# terns
# trays 1 2 3 4 6
2 1 0.99 0.96 0.92 0.84
3 1 0.92 0.95 0.91 0.85
2. Current rating (SA)
Equivalent load current - K2

H OW ?

In air perforated cable trays

T=40 °C
L=100 m
2 cable trays – 4 cables

# terns
# trays 1 2 3 4 6
2 1 0.99 0.96 0.92 0.84
3 1 0.92 0.95 0.91 0.85
2. Current rating (SA)
Equivalent load current

H OW ?
Io >= Ib / (k1 · k2)

• k1 = 0,91
• k2 = 0,92
• Ib = 50 A

Io >= 50 / (0,91 · 0,92) = 59,72 A

2. Current rating (SA)
Current carring capacity H OW ?

FG7(O)R
Rated Approx. Insulant Maximum Approx. Maximum 30°C 30°C in air
section Conductor average external weight resist. at in air in pipe
diameter thickness diameter 20°C DC
(mm2) (mm) (mm) (mm) (kg/km) (Ω/km) (A) (A)

1.5 1.5 0.7 12.5 170 13.3 23 19.5

2.5 1.9 0.7 7.2 65 7.98 32 26
4 2.4 0.7 7.8 80 4.95 42 35

(CEI-UNEL 35375 table )

6 3 0.7 16.2 370 3.30 54 44
10 4.1 0.7 18.2 530 1.91 75 60
16 5.2 0.7 20.6 740 1.21 100 80
25 6.3 0.9 24.5 1060 0.78 127 105
35 7.7 0.9 27.3 1420 0.554 158 128
2. Current rating (SA)
Current carring capacity H OW ?

FG7(O)R
Rated Approx. Insulant Maximum Approx. Maximum 30°C 30°C in air
section Conductor average external weight resist. at in air in pipe
diameter thickness diameter 20°C DC
(mm2) (mm) (mm) (mm) (kg/km) (Ω/km) (A) (A)

1.5 1.5 0.7 12.5 170 13.3 23 19.5

2.5 1.9 0.7 7.2 65 7.98 32 26
4 2.4 0.7 7.8 80 4.95 42 35

(CEI-UNEL 35375 table )

6 3 0.7 16.2 370 3.30 54 44
10 4.1 0.7 18.2 530 1.91 75 60
16 5.2 0.7 20.6 740 1.21 100 80
25 6.3 0.9 24.5 1060 0.78 127 105
35 7.7 0.9 27.3 1420 0.554 158 128

SA = 10 mm2
3. Voltage drop (SB)

DATA:
• Maximum voltage drop (standard)
• Cable R and X
• Line length (L)
• Load Current I (standard)
• Phase displacement (ϕ) (standard)

∆V(S) = K L I (R cosϕ + X sinϕ) < ∆VM

K = 2 for single-phase lines

K = √(3) for tree-phase lines
3. Voltage drop (SB)

Load
I=50 A, 400 V 3 phase H OW ?
Installation
In air perforated cable trays
T=40 °C
L=100 m

Grouping
2 cable trays – 4 cables

Voltage drop
steady-state 2%
inrush 10%

Cable Type
3 conductors – EPR
3. Voltage drop (SB)
Resistance H OW ?

Rated d.c. a.c. d.c. a.c.

section (Ohm/km) (Ohm/km) (Ohm/km) (Ohm/km)
(mm2)

In air perforated cable trays

Flexible Flexible Rigid Rigid
conductor conductor conductor conductor

1.5 16.95 16.95 15.4 15.4

2.5 10.17 10.17 9.45 9.45
4 6.31 6.31 5.88 5.88

T(r)=90°C
S=6 mm2
L=100 m
6 4.20 4.20 3.93 3.93
10 2.43 2.43 2.33 2.33
16 1.54 1.54 1.47 1.47
25 0.99 0.99 0.93 0.93
3. Voltage drop (SB)
Resistance H OW ?

Rated d.c. a.c. d.c. a.c.

section (Ohm/km) (Ohm/km) (Ohm/km) (Ohm/km)
(mm2)

In air perforated cable trays

Flexible Flexible Rigid Rigid
conductor conductor conductor conductor

1.5 16.95 16.95 15.4 15.4

2.5 10.17 10.17 9.45 9.45
4 6.31 6.31 5.88 5.88

T(r)=90°C
S=6 mm2
L=100 m
6 4.20 4.20 3.93 3.93
10 2.43 2.43 2.33 2.33
16 1.54 1.54 1.47 1.47
25 0.99 0.99 0.93 0.93
3. Voltage drop (SB)
Reactance H OW ?

Rated Unipolar Multipolar Unipolar Multipolar

section (Ohm/km) (Ohm/km) (Ohm/km) (Ohm/km)
(mm2)

G-SETTE G-SETTE G-SETTE + G-SETTE +

1.5 0.146 0.103 0.144 0.100

In air perforated cable trays

2.5 0.135 0.095 0.132 0.094
4 0.126 0.090 0.122 0.087
6 0.118 0.085 0.144 0.083
10 0.106 0.079 0.105 0.078

T(r)=90°C
L=100 m
S=6mm2

F=50 Hz
16 0.099 0.076 0.098 0.075
25 0.095 0.075 0.093 0.074
Elastomeric insulation
3. Voltage drop (SB)
Reactance H OW ?

Rated Unipolar Multipolar Unipolar Multipolar

section (Ohm/km) (Ohm/km) (Ohm/km) (Ohm/km)
(mm2)

G-SETTE G-SETTE G-SETTE + G-SETTE +

1.5 0.146 0.103 0.144 0.100

In air perforated cable trays

2.5 0.135 0.095 0.132 0.094
4 0.126 0.090 0.122 0.087
6 0.118 0.085 0.144 0.083
10 0.106 0.079 0.105 0.078

T(r)=90°C
L=100 m
S=6mm2

F=50 Hz
16 0.099 0.076 0.098 0.075
25 0.095 0.075 0.093 0.074
Elastomeric insulation
3. Voltage drop (SB)
Size selection H OW ?

∆V(S) = K L I (R cosϕ + X sinϕ) < ∆VM

K = √(3)
R(6)= 2.430 (ohm/km)
X(6)=0.078 (ohm/km)
L=100 m
cosϕ =0.8

S= 6 mm2 - ∆V(6) =17.24 V ∆V% = ∆V/V = 4 .31% > 2%

S=10 mm2  ∆V% = 4.3 % >2%
S=16 mm2  ∆V% = 2.7% > 2%

S=25 mm2  ∆V% = 1.8%< 2% ∆V(25)= 7.25 V

3. Voltage drop (SB)
Inrush Current

∆V(r) = K L I (R cosϕ + X sinϕ)

∆V<= ∆V(max on start up)

DATA
•I = start-up current
•cosϕ=0.2 for motors / cosϕ=0 for capacitors
•K = √(3) for tree-phase / K = 2 for single-phase
•R= resistance in the service temperature
•X= reactance in service of the cable (AC lines only)
•L= lenght
3. Voltage drop inrush current (SC)

Load
I=50 A, 400 V 3 phase H OW ?
Installation
In air perforated cable trays
T=40 °C
L=100 m

Grouping
2 cable trays – 4 cables

Voltage drop
steady-state 2%
inrush 10%

Cable Type
3 conductors – EPR
3. Voltage drop inrush current (SC)

∆V(r) = √(3)*0.1*300* (0.99*0.2 + 0.074*0.98)= 14.05 V

•I(r) = 6*I = 300 A •X=0.074 Ohm/km
•cosϕ=0.2 •L=100 m
•K = √(3) •S=25 mm 2
•R= 0.99 Ohm/km •INRUSH <=10% V

∆V(r%)= (14.05*100) = 3.5% < 10%

400

minimum section
SC=25mm 2
4. Short circuit (SD)

Max
min

short circuit current

4. MAX Short circuit (SD)

The max short circuit current accepted by a conductor with section S

is calulated with the following formula

Isc (max) = S • C
√T
S ≥ = Isc √T
C
• T = short circuit duration (s)
• S = cross-section of copper conductor (mm2)
• Icc = short circuit current (A)
• C is a coefficient depending on initial and final temperature
4. MAX Short circuit (SD)

Load
I=50 A, 400 V 3 phase H OW ?
Installation
In air perforated cable trays
T=40 °C
L=100 m

Grouping
2 cable trays – 4 cables

Voltage drop
steady-state 2%
inrush 10%

Cable Type
3 conductors – EPR
5. MAX Short circuit (SD1)

T(in) T(fin)
°C 140 160 180 200 220 250 H OW ?
90 86 100 112 122 131 143

85 90 104 115 125 134 146

80 94 108 119 129 137 149

75 99 111 122 132 140 151

70 103 115 125 135 143 154

65 107 119 129 138 146 157

60 111 122 132 141 149 160

50 118 129 139 147 155 165

40 126 136 145 153 161 170

30 133 143 152 159 166 176

C coefficient values for copper conductors are dependent on the temperature difference between
start and end of short-circuit, according to the table 2.02.02 of the CEI 11-17 standard
5. MAX Short circuit (SD1)

T(in) T(fin)
°C 140 160 180 200 220 250 H OW ?
90 86

90
100

104
112

115
122

125
131

134
143

146
C (G7)
85
80 94 108 119 129 137 149

75 99 111 122 132 140 151

70 103 115 125 135 143 154

65 107 119 129 138 146 157

60 111 122 132 141 149 160

50 118 129 139 147 155 165

40 126 136 145 153 161 170

30 133 143 152 159 166 176

C coefficient values for copper conductors are dependent on the temperature difference between
start and end of short-circuit, according to the table 2.02.02 of the CEI 11-17 standard
5. MAX Short circuit (SD1)

T(in) T(fin)
°C 140 160 180 200 220 250 H OW ?
90 86 100 112 122 131 143

85 90 104 115 125 134 146

80 94 108 119 129 137 149

75 99 111 122 132 140 151

70 103 115 125 135 143 154

C (PVC)
65 107 119 129 138 146 157

60 111 122 132 141 149 160

50 118 129 139 147 155 165

40 126 136 145 153 161 170

30 133 143 152 159 166 176

C coefficient values for copper conductors are dependent on the temperature difference between
start and end of short-circuit, according to the table 2.02.02 of the CEI 11-17 standard
5. MAX Short circuit (SD1)

Data: the specific energy exceeding the protective equipment (I2t)

Insulation Cu Al
EPR 143 86
PVC 115 74
XLPE 143 86

H OW ?
5. MAX Short circuit (SD1)

H OW ?
Isc (max) = S • C = 1.78 kA
√T

SD ≥ = Isc √T = 25 mm2
C

•C=143
•T= 4 s
5. Min short circuit current

neutral NOT distributed conductor neutral distributed conductor

𝟎𝟎, 𝟓𝟓 𝑼𝑼 𝟎𝟎, 𝟖𝟖 𝑼𝑼𝑼𝑼

𝑰𝑰𝑰𝑰𝑰𝑰 = 𝑰𝑰𝑰𝑰𝑰𝑰 =
𝟐𝟐𝟐𝟐 𝑳𝑳
𝟏𝟏, 𝟓𝟓 � 𝟏𝟏, 𝟓𝟓 �(𝟏𝟏 + 𝒎𝒎)
𝑺𝑺 𝑺𝑺

• U = line voltage supplied • Uo = phase rating voltage

• ρ = resistivity of the conductor • m= ratio of the neutral
compounds at 20 °C, ohm • mm2 conductor resistance and the
(0,018 for Cu - 0,027 for Al) phase conductor resistance
• L = length of protected conductor
• S = conductor cross-section
• Icc = short-circuit current
6. Min Short circuit (SD2)

minimum short-circuit current

H OW ?
0,8 U 0.8 (400)
Icc(min) = = = 1.48 kA
1,5 ρ 2 L 1.5( 0.018) (8)
S
Icc(min) 1,5 ρ 2 L
S= = 24.97 mm2  25 mm2
0.8 U

SD4= 25 mm2
6. Min Short circuit (SD2)

neutral NOT distributed conductor

H OW ?

𝟎𝟎,𝟓𝟓 𝑼𝑼 𝟎𝟎,𝟓𝟓 𝟒𝟒𝟒𝟒𝟒𝟒

𝑰𝑰𝑰𝑰𝑰𝑰 = 𝟐𝟐𝟐𝟐 = 𝟐𝟐 𝟏𝟏𝟏𝟏𝟏𝟏 = 1,48 kA
𝟏𝟏,𝟓𝟓 � 𝑺𝑺
𝟏𝟏,𝟓𝟓 𝟎𝟎,𝟎𝟎𝟎𝟎𝟎𝟎 𝟐𝟐𝟐𝟐 𝟏𝟏𝟏𝟏^−𝟑𝟑
6. Size selection

H OW ?
S = MAX(SA, SB, SC, SD)
S = MAX(10, 25, 25, 25)= 25 mm
2

• Current rating (SA)

• Voltage drop (SB)
• Inrush current (SC)
• Short circuit (SD)
 Thank you
For more information please contact

Angelo Baggini
Università di Bergamo
Dipartimento di Ingegneria
Viale Marconi 5,
24044 Dalmine (BG) Italy
email: angelo.baggini@unibg.it

ECD Engineering Consulting and Design

Via Maffi 21 27100 PAVIA Italy

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