DEPARTMENT: ELECTRICAL

DOCUMENT NO: 44AC2700-00/E.05/0009/A4

DOCUMENT TITLE: CABLE TRAY SIZING CALCULATION

ITEM:

PROJECT NO: 44AC2700

PROJECT LOCATION: GUWAHATI, ASSAM, INDIA

PROJECT TITLE: EPCM Services for BSVI and CRU Project at Guwahati
Refinery

CLIENT: Indian Oil Corporation Limited

(WHERE APPLICABLE)
CLIENT PROJECT NO: WORK ORDER # 25293705 Dated 08.12.2017

CLIENT AUTHORIZATION: G R K Murthy

PM Authorization: Srinivas Vernekar

APPROVALS
Issue
Rev. No. Pages Revision Description Prepared Checked Approved
Date

P 12.04.18 8 Preliminary PRG PPP JNS

A 29.05.18 8 Issued for Review PRG PPP JNS

þ Entire Document DOCUMENT ISSUED FOR: (please a as applicable)

Issued this Revision o In-house Review o Purchase
o Revised Pages Only þ Client Approval o Construction
Issued this Revision o Enquiry o Design

612763188.xls Page : 1/8

 PROJECT NO: 44AC2700 Rev.: B
CLIENT: IOCL Date: 29.05.18
DOCUMENT NO: 44AC2700-00/E.05/0009/A4

RECORD OF REVISIONS
Revision
Date Revision Details
Number

12.04.18 Preliminary P

29.05.18 Issued for review A

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 CALCULATION DOC. NO. 44AC2700-00/E.05/0009/A4

COVER SHEET REV. NO. A

CONTRACT NO. / TITLE : 44AC2700 : IOCL GUWAHATI: BS VI REVAMP

ITEM NO. / NAME / SUBJECT : CABLE TRAY SIZING CALCULATION GROUP ELECTRICAL

1 OBJECTIVE
(1) TO WORK OUT CABLE TRAY SIZING CALCULATIONS FOR BSVI REVAMP PROJECT

2 BASIS OF DESIGN / INPUTS

(1) Electrical Design Basis Doc. no. 44AC2700-00/E.02/0001/A4
(2) Electrical Load list for all areas
(3) In each cable tray, 20% spare space has been considered for future cables.

3 ASSUMPTIONS
1 Due to non-availability of existing cable details, LV cables has been considered for all
type of loads (New / replace / Modification).

4 CODES , STANDARDS / STATUTORY REQUIREMENTS WITH EDITION / YEAR .

5 COMPUTER PROGRAM COMPANY STANDARDS. REFERENCE DOCUMENTS

NIL NIL
Polycab Cable Catalogue

6 OUTPUT / CONCLUSION, IF ANY :

 CALCULATION DOC. NO. 44AC2700-00/E.05/0009/A4

SUMMARY SHEET REV. NO. A

CONTRACT NO. / TITLE : 44AC2700 : IOCL GUWAHATI: BS VI REVAMP

ITEM NO. / NAME / SUBJECT : CABLE TRAY SIZING CALCULATION GROUP ELECTRICAL

A SUMMARY - 6.3kV CABLE TRAY

Power Cable Tray Control Cable Tray
S.No From To Remarks
Width (mm) Width (mm)
CRU Substation Main
1 TPS 1 # 600 1 # 600
incomer -1 & 2
Trafos. Located in CRU
2 CRU Substation 1 # 600
Substation

B SUMMARY - 415V CABLE TRAY

Power Cable Tray Control Cable Tray
S.No From To Remarks
Width (mm) Width (mm)
1 CRU Substation Outdoors-IndeselectG 2 # 750 1 # 750
2 CRU Substation Inside Substation 7 # 750 2 # 600
3 CRU Substation lighting-Indoors 1 # 150
4 New Unit HT s/s HDT / HGU-Outdoors 2 # 750 1 # 750
5 CRU Substation DG Set Cable 2 # 600 1 # 150
6 CRU Substation Outdoors-MS Blending 1 # 300 1 # 300
7 CRU Substation CDU-flare mitigation loads 3 # 750 1 # 600

These cables follow the existing

8 CRU Substation 3-cut splitter cable trays and move further to 3
cut splitter area.
9 New Unit HT s/s NHDT-ISOM 1 # 600 1 # 600
Notes:
1 6.3kV Softstarter cable run will be within S/s and hence, cable will be run in existing cable tray.
2 Cable trays for cables laid in new unit HT substation are considered in existing cable trays.

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 ITEM NO. / NAME / SUBJECT : CABLE TRAY SIZING CALCULATION-HV cables (6.3kV)

DOC. NO. : 44 44AC2700-00/E.05/0009/A4

REV. A

Cable Size No. of Type of POWER Cable Intertrip OD Power Cables Control Cables
Equipment Service Description Nameplate Feeder Runs Cable OD (mm) (mm) Total OD Total OD
Sr. No. BUS NO. Location AREA Qty
Number Drive Description Rating Type (mm) (mm)

1 CRU From 6.6kV Non-essential Panel (location: TPS S/s-

2 Power 1Cx630 3 A2XFY 71.5 19 429 38
incomer 01) to CRU S/s Main incomer 1 & 2
2 IndeselectG CRU transformer feeder to IndeselectG 2MVA 2 Power 1Cx630 1 A2XFY 71.5 19 143 38
3
Flare CRU transformer feeder to FLARE mitigation loads 2MVA 2 Power 1Cx630 1 A2XFY 71.5 19 143 38

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 ITEM NO. / NAME / SUBJECT : CABLE TRAY SIZING CALCULATION

DOC. NO. : 44AC2700-00/E.05/0009/A4

AREA: INDESELECTG / CRU Substation REV. A

POWER LCS Cable Emergency Space PTC CABLE RTD CABLE BTD CABLE Power Cables Control Cables
Cable OD OD PB Cable OD heater Cable OD OD OD Total OD Total OD (mm) Total OD (mm)
CABLE Equipment Service Description Nameplate Feeder No. of Type of
Sr. No. BUS NO. Location Qty Cable Size (mm) (mm) (mm) OD (mm) (mm) (mm) (mm) power & control
LOCATION Number Drive Description Rating (kW) Type Runs Cable
(mm) cables

PMCC (LOCATION: CRU SUBSTATION)

1
OUTDOOR 04-P-701 A/B DCU CG Splitter Reflux Pumps 9.3 2 Motor 3Cx25 1 A2XFY 20.5 19 41 38 79

2 OUTDOOR 04-P-702 A/B Heavy Coker Naphtha Pumps 5.5 2 Motor 3Cx10 1 A2XFY 19 19 38 38 76
3
OUTDOOR 04-AC-801 Reactor Product Air Cooler 5.5 2 Motor 3Cx16 1 A2XFY 18.5 19 37 38 75

4 OUTDOOR 04-K-801 A/B Recycle Gas Compressor 45 2 Motor 3Cx240 1 A2XFY 49 19 98 38 136
5 OUTDOOR Auxilliary system Lube Oil Heater 1.5 1 Power 4Cx10 1 A2XFY 20.5 21 0 21
6 OUTDOOR 04-P-801 A/B Feed Pumps 37 2 Motor 3Cx95 1 A2XFY 33.5 19 14 67 66 133
7 OUTDOOR 04-P-802 A/B Stripper Reflux Pumps 2.2 2 Motor 3Cx4 1 A2XFY 16 16.5 32 33 65
8 OUTDOOR 04-P-803 A/B Cold Feed Pumps 7.3 2 Motor 3Cx25 1 A2XFY 20.5 19 14 41 66 107
9 OUTDOOR 04-P-804 A/B DMDS Dosing Pumps 2.2 2 Motor 3Cx4 1 A2XFY 16 16.5 32 33 65
10 OUTDOOR 04-EH-801 Electric Heater panel 600 1 Power 4Cx240 6 A2XFY 54 19 324 19 343
11 OUTDOOR Heat Tracing panel 20 1 Power 4Cx240 1 A2XFY 54 54 0 54
12 OUTDOOR LTG. PANEL 63A 2 Power 4Cx35 1 A2XFY 25 50 0 50
13 OSBL 007AB-P-01 A/B MS Blending Booster Pump 30 2 Power 3Cx70 1 A2XFY 30 19 60 38 98
14 OSBL 007AB-M-02 Dye Injection Package 10 1 Power 4Cx35 1 A2XFY 25 25 0 25
15 OSBL 007AB-M-01 MS Blending Package 10 1 Power 4Cx35 1 A2XFY 25 25 0 25
16 OSBL 007AB-P-02 A/B DOSING PUMP 15 2 Power 4Cx35 1 A2XFY 25 19 50 38 88
17 OSBL 007AB-V-01 DRY POWER HOPPER-MOTOR 5.5 1 Power 4Cx35 1 A2XFY 25 19 25 19 44
18 3-CUT
Outdoor 55-P-03 A/B 3 CUTS SPLITTER FEED PUMPS 6.1 2 Motor 3Cx25 1 A2XFY 20.5 19 41 38 79
SPLITTER
19 Outdoor CDU/NSF E-003 Overhead air cooler 7.5 3 Motor 3Cx35 1 A2XFY 23 19 69 57 126
20 Outdoor CDU/NSF P-005 A/B reflux pump 37.0 2 Motor 3Cx120 1 A2XFY 35.5 19 71 38 109
21 Outdoor MSQ AC-02 Overhead air cooler 4.0 6 Motor 3Cx25 1 A2XFY 20.5 19 123 114 237
22 Outdoor MSQ P-05 A/B reflux pump 37.0 2 Motor 3Cx120 1 A2XFY 35.5 19 71 38 109
23 Outdoor HGU/HDT AC-02 Overhead air cooler 11.0 3 Motor 3Cx35 1 A2XFY 23 19 69 57 126
24 Outdoor HGU/HDT P-06 A/B reflux pump 30.0 2 Motor 3Cx150 1 A2XFY 40.5 19 81 38 119
25 Outdoor /
HDT 49-AC-02 Stripper Condenser 11 4 Motor 3Cx35 1 A2XFY 23 19 16.1 92 140 232
Indoor
26 Outdoor /
HDT 49-AC-01 Reactor Effluent Condensor 22 3 Motor 3Cx70 1 A2XFY 30 19 16.1 90 105 195
Indoor
27 Outdoor /
HDT 49-K-02 A/B Net Gas Compressors 75 2 Motor 3Cx120 4 A2XFY 35.5 19 18.975 18 284 112 396
Indoor
25 Outdoor HGU 48-E-10 Prereformer Startup Electrical Heater 450 1 Power 4Cx240 6 A2XFY 54 19 14 324 33 357
25 INDOOR DC UPS 160A 2 Power 4Cx150 1 A2XFY 43.5 87 0 87
26 INDOOR DCDB 160A 1 Power 4Cx120 1 A2XFY 39 39 0 39
27 INDOOR SIGNALS 2 Power 1 A2XFY 19 0 38 38
28 INDOOR Loads 10 Power 4Cx10 1 A2XFY 20.5 205 0 205
29 INDOOR HVAC 250A 2 Power 4Cx240 1 A2XFY 54 108 0 108
30 INDOOR Ltg. Trafo. 100kVA 1 Power 4Cx240 1 A2XFY 54 54 0 54
31 INDOOR MLDB 250A 1 Power 4Cx240 1 A2XFY 54 54 0 54
32 INDOOR LTG. PANEL 63A 1 Power 4Cx35 1 A2XFY 25 25 0 25
33 INDOOR ASB 250A 1 Power 4Cx240 1 A2XFY 54 54 0 54
34 INDOOR WELDING RECEPTACLES 63A 1 Power 4Cx35 1 A2XFY 25 25 0 25
35 INDOOR PANEL-convienece sockets 63A 1 Power 4Cx35 1 A2XFY 25 25 0 25
36 INDOOR CONVINIENCE SOCKETS 63A 2 Power 4Cx35 1 A2XFY 25 50 0 50
37 INDOOR TPS TO TRAFO INCOMER-1 1 Power 2 A2XFY 19 14 14 0 47 47
38 INDOOR TPS TO TRAFO INCOMER-1 1 Power 2 A2XFY 19 14 14 0 47 47
39
INDOOR UPS-07 / UPS-08 UPS in New CRU Control room 600 1 Power 3Cx95 4 A2XFY 33.5 134 0 134

40
INDOOR UPS-09 / UPS-10 UPS in New CRU Control room 600 1 Power 3Cx95 4 A2XFY 33.5 134 0 134

41 INDOOR NON-UPS-05 NON UPS Feeder in New CRU Control room 600 1 Power 3Cx95 4 A2XFY 33.5 134 0 134
42 INDOOR NON-UPS-06 NON UPS Feeder in New CRU Control room 600 1 Power 3Cx95 4 A2XFY 33.5 134 0 134
43
Indoor CRU-HDT 48-E-10 Prereformer Startup Electrical Heater-heater panel 450 1 Power 4Cx240 3 A2XFY 54 162 0

43 INDOOR 04-EH-801 from PMCC to Electric Heater panel 600 1 Power 4Cx240 4 A2XFY 54 14 216 14 230
ACTUAL TRAY WIDTH IN mm (OUTDOOR)= 2335 1235
ACTUAL TRAY WIDTH IN mm (INDOOR)= 3975 1381
20 % MARGIN FOR CONTINGENCY (OUTDOOR)= 2801 1482
20 % MARGIN FOR CONTINGENCY (INDOOR)= 4769 1657
CABLE LAYING (OUTDOOR)= 1 2
CABLE LAYING (INDOOR)= 1 2
MAX TRAY WIDTH mm (OUTDOOR)= 750 750
MAX TRAY WIDTH mm (INDOOR)= 750 750
NO OF TRAYS REQUIRED { L / (M-50 )mm } (OUTDOOR) = 4.01 1.06
NO OF TRAYS REQUIRED { L / (M-50 )mm } (INDOOR) = 6.82 1.19

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 ITEM NO. / NAME / SUBJECT : CABLE TRAY SIZING CALCULATION

DOC. NO.: 44AC2700-00/E.05/0009/A4

AREA: HDT / HGU/ ISOM / 3 CUT SPLITTER REV. A

Cable Size No. of Type of POWER LCS Cable Emergency Space PTC CABLE RTD CABLE BTD CABLE Power Cables Control Cables Total OD (mm) Total OD (mm) Total OD (mm)
Equipment Service Description Nameplate Feeder Runs Cable Cable OD OD PB Cable heater Cable OD OD OD Total OD Total OD power & control power & control SIGNAL
Sr. No. BUS NO. location AREA Qty
Number Drive Description Rating (kW) Type (mm) (mm) OD OD (mm) (mm) (mm) (mm) (mm) (Cables outside (Cables with in CABLES (RTD &
(mm) (mm) S/S) S/S) BTD Cables)
1 Outdoor HDT Auxilliary Lube Oil Pump 1.7 2 Motor 3Cx2.5 1 A2XFY 14 19 28 38 66 0
2 Outdoor HDT Auxilliary Lube Oil Pump 10.8 2 Motor 3Cx25 1 A2XFY 20.5 19 41 38 79 0
3 Outdoor HDT 49-P-01 A/B Diesel / Kerosene Transfer Pumps 61.2 2 Motor 3Cx185 1 A2XFY 44.5 19 18.975 89 76 165 0
4 Outdoor HDT 49-P-05 A/B Stripper Bottoms Pumps 45.7 2 Motor 3Cx70 1 A2XFY 30 19 60 38 98 0
5 Outdoor HDT 49-P-15 A/B Backwash Pumps 4.9 2 Motor 3Cx10 1 A2XFY 19 19 38 38 76 0
6 Outdoor HDT 49-P-16 Sulfide Transfer Pump 0.5 1 Motor 3Cx2.5 1 A2XFY 14 16.5 14 17 31 0
7 Outdoor HDT 49-P-06 A/B Stripper Bottoms Pumps 14.3 2 Motor 3Cx50 1 A2XFY 25.5 19 51 38 89 0
8 Outdoor HDT HEAT TRACING 10 1 Power 4Cx50 1 A2XFY 28 28 0 28 0
9 Outdoor HDT 49-K-03 A/B Makeup Gas Compressors 1363.6 2 Motor A2XFY 0 0 0 0
10 Outdoor HDT 49-P-03 A/B Charge Pumps 720.4 2 Motor A2XFY 0 0 0 0
11 Outdoor HDT 49-P-03 A/B Wild Naphtha Stripper Bottom Pump 9.3 2 Motor 3Cx10 1 A2XFY 19 19 14 14 18 32.5 28 38 130 168 121
12 Outdoor HGU 48-AC-01 Process Gas Air Cooler 15 2 Motor 3Cx35 1 A2XFY 23 19 14 14 46 94 140 0
13 Outdoor HGU 48-AC-01 Process Gas Air Cooler 15 1 VFD 4Cx95 1 A2XFY 35 19 14 14 18 35 65 100 0
14 Outdoor HGU Auxilliary system Lube Oil Pump 1.4 2 Motor 3Cx4 1 A2XFY 16 19 32 38 70 0
15 Outdoor HGU CW Pump 10 2 Motor 3Cx25 1 A2XFY 20.5 19 41 38 79 0
16 Outdoor HGU Lube Oil Heater 2 1 Power 4Cx10 1 A2XFY 20.5 21 0 21 0
17 Outdoor HGU 48-P-01 A/B Naphtha Feed Pump 76 2 Motor 3Cx120 2 A2XFY 35.5 19 14 14 18 142 130 272 0
18 Outdoor HGU 48-P-04 A/B Naphtha booster Pump 4.4 2 Motor 3Cx10 1 A2XFY 19 19 14 38 66 104 0
19 Outdoor HGU 48-K-03A/B Combustion Air Fan (FD Fan) 90 1 VFD 4Cx240 3 A2XFY 54 19 14 14 18 162 65 227 0
20 Outdoor HGU 48-K-04 Flue Gas Fan (ID Fan) 200 1 VFD 4Cx240 5 A2XFY 54 19 14 14 18 270 65 335 0
21 Outdoor HGU 48-X-05 PSA Unit 5 1 Power 4Cx25 1 A2XFY 23 23 0 23 0
22 Outdoor NHT ISOM 56-P-0120 A/B Deisopentaniser Bottom Pumps 10 2 Motor 3Cx16 1 A2XFY 18.5 19 37 38 75 0
23 Outdoor NHT ISOM 56-P-0121 A/B Deisopentaniser Reflux Pumps 20 2 Motor 3Cx35 1 A2XFY 23 19 46 38 84 0
24 Outdoor NHT ISOM 56-AC-114 Deisopentaniser Condenser 20 1 Motor 3Cx35 1 A2XFY 23 19 14 23 33 56 0
ACTUAL TRAY WIDTH IN mm (OUTDOOR)= 1197 973 2385 121
ACTUAL TRAY WIDTH IN mm (INDOOR)=
20 % MARGIN FOR CONTINGENCY (OUTDOOR)= 1436 1168 2862 145
20 % MARGIN FOR CONTINGENCY (INDOOR)= 0 0 0 0
CABLE LAYING (OUTDOOR)= 1 2
CABLE LAYING (INDOOR)=
MAX TRAY WIDTH mm (OUTDOOR)= 750 750
MAX TRAY WIDTH mm (INDOOR)=
NO OF TRAYS REQUIRED { L / (M-50 )mm } (OUTDOOR) = 2.06 0.84
NO OF TRAYS REQUIRED { L / (M-50 )mm } (INDOOR) =

Page 7 of 8
 Aluminium/copper (upto
Cable Size 10sq.mm)-XLPE Reference: Cable OD data selected from
(Sq.mm)
(OD) no tolerance Polycab Catalogue with out tolerances
3Cx4 16 16
3Cx6 17 17
3Cx10 19 19
3Cx16 18.5 18.5
3Cx25 20.5 20.5
3Cx35 23 23
3Cx50 25.5 25.5
3Cx70 30 30
3Cx95 33.5 33.5
3Cx120 35.5 35.5
3Cx150 40.5 40.5
3Cx185 44.5 44.5
3Cx240 49 49
3Cx300 53 53
3Cx400 58.5 58.5
3Cx500 67 67
3Cx630 73 73
4Cx4 17.5 17.5
4Cx6 18.5 18.5
4Cx10 20.5 20.5
4Cx16 20 20
4Cx25 23 23
4Cx35 25 25
4Cx50 28 28
4Cx70 32 32
4Cx95 35 35
4Cx120 39 39
4Cx150 43.5 43.5
4Cx185 48 48
4Cx240 54 54
4Cx300 59.5 59.5
4Cx400 66.5 66.5
3Cx2.5 14 14
7Cx2.5 16.5 16.5
10Cx2.5 19 19
2Px1.5 18 18 Instrumentation reference
4Tx1.5 28 28 Instrumentation reference
8Tx1.5 32.5 32.5 Instrumentation reference

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