TCE CONSULTING ENGINEERS LIMITED

30421007-3CL- SHEET i OF i
00013-P0B
4.16 kV MV CABLE
SIZING REPORT

SAUDI ELECTRICITY COMPANY

EASTERN OPERATING AREA
Dammam, Saudi Arabia

GENERATION EXPANSION OF ARAR POWER PLANT

(CONTRACT NO : 30421007/00)

DESIGN BASIS
FOR
4.16 kV MV CABLE SIZING

DOCUMENT NO : 30421007-3CL-00013-P0B

NOVEMBER 2004

ENGINEERING CONSULTANT
TCE CONSULTING ENGINEERS LIMITED
73/1, ST.MARK'S ROAD
BANGALORE 560001
INDIA

CONTRACTOR:
AL-TOUKHI COMPANY FOR INDUSTRY & TRADING
P.O.BOX 497, RIYADH 11411, KINGDOM OF SAUDI ARABIA
TEL.00966-1-4633660 : FAX.00966-1-4631150

P0B
MP SR
01.11.2004

P0A
MP SR
08.09.2004

REV NO. DATE PREPARED BY CHECKED BY CLEARED BY APPROVED BY

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 GENERATION EXPANSION OF ARAR POWER PLANT
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ARAR 4.16kV CABLE SIZING REPORT DOCUMENT NO. 30421007-3CL-00013-P0B.

CONTENTS

SECTION DESCRIPTION

1.0 SCOPE

2.0 STANDARDS & REFERENCES

3.0 GENERAL PARAMETERS

4.0 SIZING CRITERIA

5.0 CONCLUSION

6.0 CABLE SIZING REPORT SUMMARY

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 GENERATION EXPANSION OF ARAR POWER PLANT
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ARAR 4.16 kV CABLE SIZING REPORT DOCUMENT NO. 30421007-3CL-00013-P0B

1.0 SCOPE

Scope of this report is to calculate the 4.16kV Cable sizes(3.6/6kV Grade) for the following 3 cases.

CASE-1
4.16 kV Cable size (3.6/6kV Grade) from 4.16kV Station Transformer T 401 orT 402 to 4.16kV Station
Switchgear incoming breakers.

CASE-2
4.16 kV Cable size (3.6/6kV Grade) from 4.16kV Station Switchgear to Station Aux Transformer T201 or T202.

CASE-3
4.16 kV Cable size (3.6/6kV Grade) from 4.16kV Station Switchgear to Starting Motors GT#7 or GT#8

2.0 STANDARDS & REFERENCES

2.1 IEC 60986-short circuit sizing.

2.2
IEC 60364-5-523 Selection and erection of electrical equipment-Current Carrying capacities in wiring system.

2.3 SES-P-104.03 - Cable Selection -Engineering standards.

2.4 Key One Line Diagram for Arar Plant Drawing No: KA667481 REV-P0D

2.5 SAUDI CABLE COMPANY - Medium Voltage Cables Catalogues

3.0 GENERAL PARAMETERS

- Depth of Burried Cables = 1 meter

- Ground Temperature at a depth of 1 meter = 35 Deg C
- Average Thermal Soil resistivity = 2 Deg C-m/w
- Ambient air Temperature = 50 Deg C
- Short Circuit current = 25 kA for 3 second for CASE#1
25 kA for 1 second for CASE#2 & CASE#3
4.0 SIZING CRITERIA

The Power Cable size shall be selected on the basis of :

- Short circuit Rating.

- Current Carrying Capacity.
- Permissible Voltage Drop.

4.1 SHORT CIRCUIT SIZING.

According to SES-P-104.03 Engineering standards Cl No:4.9.6 the minimum cable cross section may be
calculated with the formula:
142 x S
I =
t
Where,
I = Maximum Allowable conductor Short Circuit Current in Amps
t = Duration of Short circuits in seconds
S = Cross Sectional Area of Current Carrying conductor in Sqmm
K = Temperature co-efficient of conductor resistance. = 142 for copper XLPE
therefore,
Ix t
S =

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ARAR 4.16 kV CABLE SIZING REPORT DOCUMENT NO. 30421007-3CL-00013-P0B

S =
142

FOR CASE-1

25000 x 3
S =
142

S = 304.930 Sqmm

Minimum nearest cable size is 400 Sqmm (Refer SAUDI CABLE COMPANY)

However,As per the Cl.No. 3.03-13 of PTS-1022, page 40 of 336, the size of cable from Station
Transformer to Station Switchgear is selected as 1C x 630 Sqmm/Phase Cu, XLPE Unarmoured.

FOR CASE-2
25000 x 1
S =
142

S = 176.056 Sqmm

Minimum nearest cable size 185 Sqmm (Refer SAUDI CABLE COMPANY)

However, as per the Cl.No. 3.03-13 of PTS-1022, page 40 of 336, the size of cable from Station
Switchgear to Station Aux Transformers T201or T202 is selected as 1C x 630 Sqmm/Phase Cu, XLPE
unarmoured.

FOR CASE-3
25000 x 1
S =
142

S = 176.056 Sqmm

Minimum nearest cable size 185 Sqmm (Refer SAUDI CABLE COMPANY)

However, as per the Cl.No. 3.03-14 of PTS-1022, page 40 of 336, the size of cable from Station
Switchgear to Starting Motor is selected as 3C x185 Sqmm, Cu, XLPE Unarmoured.

4.2 CURRENT CARRYING CAPACITY

CASE-1 from 4.16kV Station Transformer T 401 orT 402 to 4.16kV Station Switchgear incoming
breakers.

The total load current to be 7.5 MVA

carried by 4.16kV cable to = = 1040.92Amps
Station Switchgears 3 x 4.16 kV

CASE-2 from 4.16kV Station Switchgear to Station Aux Transformer T201 or T202.

The total load current to be 3 MVA

carried by 4.16kV cable to
= = 416.37 Amps
Station Aux Transformer
T201or T202

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ARAR 4.16 kV CABLE SIZING REPORT DOCUMENT NO. 30421007-3CL-00013-P0B

The total load current to be
carried by 4.16kV cable to
= = 416.37 Amps
Station Aux Transformer
3 x 4.16 kV
T201or T202

According to SAUDI CABLE COMPANY Catalogues for Medium Voltage Cable System,the nominal
current carrying capacities are,
FOR CASE-1 & case 2
Current Carrying capacity
Laying Conditions(in duct) in Amps for 1C x 630
Sqmm
Laid directly in ground or duct ways, Ground
temp.in flat formation 30 DegC and Thermal
665
resistivity of soil = 1.2K m/W, depth of laying =
0.8m
Laid directly in ground or duct ways, Ground
temp.in trefoil formation 30 DegC and Thermal
720
resistivity of soil = 1.2K m/W, depth of laying =
0.8m

Current Carrying capacity

Laying Conditions (in Air) in Amps for 1C x 630
Sqmm
Laid in Air (tray),in flat formation Ambient
980
Temperature 40 Deg C

Laid in Air (Tray), in trefoil formation Ambient

960
Temperature 40 Deg C

FOR CASE-1 & CASE-2

Derating factor Kd for 1C x 630 Sqmm Cable Laid in Duct ways :(for both Flat/trefoil formation)

-Ground Temperature 35 DegC K1 = 0.95

-Thermal Resistivity of soil 2.0DegC m/W K2 = 0.84
-Depth of Laying 1m K3 = 0.98
-Group Rating Factor K4 = 0.80
-according to:
- installation system = spacing between two ducts(center line to center line) equl 0.3m
- No of ducts in ground = 3
Derating Factor Kd = K1 x K2 x K3 x K4
Kd = 0.6256

Derating factor Ka for 1C x 630 Sqmm Cable installed in free air:(for both Flat/trefoil formation)

- ambient Air Temperature 50 DegC K5 = 0.89

- Laying on Cable Tray(in touching form) K6 = 0.86
according to:
- installation system in three phase circuits
- No of trays = 3

Derating Factor Ka = K5 x K6
Ka = 0.7654

According to the above, the maximum current carrying capacity of the selected 1C x 630Sqmm cable
as follows

Maximum current carrying capacity of 1C x 630Sqmm Cable Laid in Duct ways(after considering
derating factor)

Laying cable in flat formation, current = 665 x Kd = 416.05

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ARAR 4.16 kV CABLE SIZING REPORT DOCUMENT NO. 30421007-3CL-00013-P0B

Laying cable in trefoil formation, current = 720 x Kd = 450.46

Maximum current carrying capacity of 1C x 630Sqmm cable Laid in Air(Cable Tray)

(after considering derating factor)

Laying cable in flat formation, current = 980 x Ka = 750.09

Laying cable in trefoil formation, current = 960 x Ka = 734.78

FOR CASE-1 (From Station Transformer to Staion Switchgear incoming breakers)

As per above calculation, 3-Nos of 1C x 630 Sqmm/Phase cable can carry the required load current
of 1040.96Amps under all site conditions when cable laid in duct ways.

As per above calculation, 2-Nos of 1C x 630 Sqmm/Phase cable can carry the required load current
of 1040.96Amps under all site conditions when cable laid in Air(Cable Tray)

FOR CASE-2 (From Station Switchgear to Station Aux Transformer)

Also as per above calculation,1C x 630 Sqmm/Phase cable can carry the required load current
of 416.37 Amps under all site conditions.

CASE-3 from 4.16kV Station Switchgear to Starting Motor GT#7 or GT#8

The total load current to be 596.8kW

carried by 4.16kV cable to = = 102.575 Amps
starting motors 3x4.16x0.85x0.95

The cable selected as 3C x 185 Sqmm size)

Current Carrying capacity
Laying Conditions(in duct) in Amps for 3C x 185
Sqmm
Laid directly in ground or duct ways, Ground
temp.30 Deg C and Thermal resistivity of soil = 380
1.2K-m/W, depth of laying = 0.8m

Current Carrying capacity

Laying Conditions (in Air) in Amps for 3C x 185
Sqmm
Laid in Air (tray),in Ambient Temperature 40 Deg
410
C

The following Derating factors have been considered as per SAUDI CABLE COMPANY Catalogues
for the site conditions specified:

Derating factor Kd for 3C x185 Sqmm Cable Laid in Duct ways :

- Ground Temperature 35 DegC K1 = 0.95

- Thermal Resistivity of soil 2.0Deg C-m/W K2 = 0.87
- Depth of Laying 1m K3 = 0.99
- Group Rating Factor K4 = 0.90
-according to:
- installation system = spacing between two adjacent (center line to center line) ducts equal 0.3m
- No of ducts in ground = 2
Derating Factor Kd = K1 x K2 x K3 x K4
Kd = 0.7364

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ARAR 4.16 kV CABLE SIZING REPORT DOCUMENT NO. 30421007-3CL-00013-P0B

Derating factor Ka for 3C x185 Sqmm Cable installed in free air:

- ambient Air Temperature 50 DegC K5 = 0.89

- Laying on Cable Tray(in touching form) K6 = 0.7
according to:
- installation system in three phase circuits
- No of trays = 3

Derating Factor Ka = K5 x K6
Ka = 0.6230

According to the above, the maximum current carrying capacity of the selected 3C x 185 Sqmm cable
as follows

Maximum current carrying capacity of 3C x 185 sqmm Cable Laid in Duct ways(after considering
derating factor)

Laying cable in duct, current = 380 x Kd = 279.84

Maximum current carrying capacity of 3C x 185 Sqmm Cable Laid in Air(Cable Tray)
(after considering derating factor)

Laying cable in Cable Tray, current = 410 x Ka = 255.43

From 4.16kV Station Switchgear to Starting motor

As per above calculation,3C x 185 Sqmm cable size can carry the required load current
of 102.575 Amps under all site conditions.

4.3 VOLTAGE DROP SIZING

The Voltage drop check is calculated as follows :

V% = 3 x(RCOS + XSIN) x I x L x 100 /Un for three phase system
Where, FOR CASE-1 FOR CASE-2
1C x 630 1C x 630
COS = Power Factor = 0.8 0.8
SIN = = 0.6 0.6
I = Full load Current in A = 520.46 416.37
L = Length in Km = 0.05 0.075
Un = Cable Voltage in V = 4160 4160
R = Resistance  /Km = 0.0434 0.0434
X = Reactance  /Km = 0.11 0.11

The Voltage Drop for CASE-1 from 4.16kV Station Transformer T 401 orT 402 to 4.16kV Station
Switchgear incoming breakers.

V% = 0.109 % Volts which is < 5%

Hence, Voltage drop is within the limits.

The Voltage Drop for CASE-2 from 4.16kV Station Switchgear to Station Aux
Transformer T201 or T202.

V% = 0.131 % Volts which is < 5%

Hence, Voltage drop is within the limits.

FOR CASE-3 from 4.16kV Station Switchgear to Starting Motor GT#7 or GT#8

The Voltage drop check is calculated as follows:

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ARAR 4.16 kV CABLE SIZING REPORT DOCUMENT NO. 30421007-3CL-00013-P0B

During starting
V% = 3 (I1Z1L1 + I2Z2L2)x100/Un
Where,
Un = Voltage in V = 4160

I1 is the current of Station Transformer

I1 = I2 + Base load on 4.16kV SWGR
Secondary side cable

I2 is the current of Station SWGR to Motor

I2 = 6 times the motor full load current =6x102.575 = 615.45 A
Cable during starting condition.

Base Load on 4.16kV SWGR = 1941.5kVA Refer Cl.No.5.2.2 ,page 6 of 8 of Doc

No:30421007-3CL-00006-P0A 33/4.16kV
Base Load in Amps = 269.46 Station Transformer sizing Report

Therefore, 615.45 + 296.46 I1 = 884.91 Amps

I2 = 615.45 Amps

Z1 is Impedance of Station Transformer

Z1 = R1COS1 + X1SIN1
Secondary side cable ie., 1C x 630 Sqmm

Z2 is Impedance of Station Swgr to Motor

Z2 = R2COS2 + X2SIN2
cable. ie., 3C x 185 Sqmm

Power Factor for starting COS = 0.2

SIN = 0.98

1C x 630 Sqmm Cable Length in km L1 = 0.05

R1 = Resistance  /Km = 0.0434
X1 = Reactance  /Km = 0.11

3C x 185 Sqmm Cable Length in km L2 = 0.2

R2 = Resistance  /Km = 0.129
X2 = Reactance  /Km = 0.1

Z1 = 0.12

Z2 = 0.12

The Voltage drop in cable from secondary of station Transformer to 4.16kV Motor terminal during starting
condition of 4.16kV Motor

V% = 0.849 % Volts

During Running
V% = 3 (I1Z1L1 + I2Z2L2)x100/Un
Where,
I1 is the current in Station Transformer
I1 = I2 + Base load on 4.16kV SWGR
Secondary side cable

I2 is the current in Station SWGR to Motor

I2 = Motor full load current = 102.575amps
Cable during running

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ARAR 4.16 kV CABLE SIZING REPORT DOCUMENT NO. 30421007-3CL-00013-P0B

Power Factor for Running COS = 0.85

SIN = 0.53

I1 = 372.035

I2 = 102.575

Z1 = 0.09

Z2 = 0.16

The Voltage drop during running condition of 4.16kV Motor

V% = 0.212 % Volts

5.0 CONCLUSION

CASE-1
From Station Transformers T 401 or T 402 to Station switchgear incoming breakers
3/6 kV Grade, XLPE insulated, Copper Conductor of size 3Nos-1C x 630 Sqmm/Phase,
Unarmoured cable has been selected based on the above calculations when cable laid in duct ways.

From Station Transformers T 401 or T 402 to Station switchgear incoming breakers

3/6 kV Grade, XLPE insulated, Copper Conductor of size 2Nos-1C x 630 Sqmm/Phase,
Unarmoured cable has been selected based on the above calculations when cable laid in Air (Cable Tray).

CASE-2
From Station Switchgear to Station Aux Transformers T 201 or T 202
3/6 kV Grade, XLPE insulated, Copper Conductor of size 1C x 630 Sqmm/Phase, Unarmoured
cable has been selected based on the above calculations.

CASE-3
From 4.16kV Station Switchgear to Starting motors GT#7 & GT#8
3.6/6 kV Grade, XLPE insulated, Copper Conductor of size 3C x 185 Sqmm, Unarmoured
cable has been selected based on the above calculations.

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ARAR 4.16 kV CABLE SIZING REPORT DOCUMENT NO. 30421007-3CL-00013-P0B

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DOCUMENT NO. 30421007-3CL-00013-P0B

V Grade) for the following 3 cases.

mer T 401 orT 402 to 4.16kV Station

ear to Station Aux Transformer T201 or T202.

ear to Starting Motors GT#7 or GT#8

urrent Carrying capacities in wiring system.

V-P0D

as per Cl.No.4.01.1 page 70 of

336, Cl.No.4.01.2 page 71 of
336 of PTS - 1022
nd for CASE#1
nd for CASE#2 & CASE#3

e minimum cable cross section may be

t Circuit Current in Amps

rying conductor in Sqmm

or resistance. = 142 for copper XLPE

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DOCUMENT NO. 30421007-3CL-00013-P0B

the size of cable from Station

/Phase Cu, XLPE Unarmoured.

the size of cable from Station

as 1C x 630 Sqmm/Phase Cu, XLPE

the size of cable from Station

XLPE Unarmoured.

6kV Station Switchgear incoming

former T201 or T202.

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DOCUMENT NO. 30421007-3CL-00013-P0B

Voltage Cable System,the nominal

for both Flat/trefoil formation)

center line) equl 0.3m

(for both Flat/trefoil formation)

as per IEC 60364-5-523

table 52-E5

the selected 1C x 630Sqmm cable

Laid in Duct ways(after considering

Amps

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DOCUMENT NO. 30421007-3CL-00013-P0B

Amps

Laid in Air(Cable Tray)

Amps
Amps

oming breakers)
can carry the required load current

can carry the required load current

arry the required load current

DI CABLE COMPANY Catalogues

e to center line) ducts equal 0.3m

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DOCUMENT NO. 30421007-3CL-00013-P0B

as per IEC 60364-5-523

table 52-E4

the selected 3C x 185 Sqmm cable

Laid in Duct ways(after considering

Amps

Laid in Air(Cable Tray)

Amps

required load current

three phase system

Note:
For Case-1:
The full load current for
2Runs of 1Cx630Sqmm/phase
is 1040.92A. Hence for 1Run
of 1Cx630Sqmm/phase is
considered as 1040.92/2 =
520.46Amps

r T 401 orT 402 to 4.16kV Station

r to Station Aux

or GT#7 or GT#8

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DOCUMENT NO. 30421007-3CL-00013-P0B

n 4.16kV SWGR

or full load current =6x102.575 = 615.45 A

Refer Cl.No.5.2.2 ,page 6 of 8 of Doc

No:30421007-3CL-00006-P0A 33/4.16kV
Station Transformer sizing Report

to 4.16kV Motor terminal during starting

n 4.16kV SWGR

urrent = 102.575amps

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DOCUMENT NO. 30421007-3CL-00013-P0B

ncoming breakers
s-1C x 630 Sqmm/Phase,
lations when cable laid in duct ways.

ncoming breakers
s-1C x 630 Sqmm/Phase,
lations when cable laid in Air (Cable Tray).

630 Sqmm/Phase, Unarmoured

x 185 Sqmm, Unarmoured

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DOCUMENT NO. 30421007-3CL-00013-P0B

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6.0 CABLE SIZING REPORT SUMMARY

ARAR 4.16kV CABLE SIZING REPORT DOCUMENT NO. 30421007-3CL-00013-P0B

FULL
LENGTH
SL LOAD CURRENT CARRYING CAPACITY OF CABLE (SINGLE CURRENT CARRYING CAPACITY OF % VOLTAGE
FEEDER DESCRIPTION LOAD VOLTAGE CABLE SIZE SELECTED DERATING FACTOR OF
NO. CURRENT RUN) CABLE AFTER DERATING FACTOR (SINGLE RUN) DROP
CABLE
IFL

CABLE LAID IN DUCT CABLE LAID IN AIR(CABLE CABLE LAID IN DUCT CABLE LAID IN AIR- CABLE LAID IN DUCT CABLE LAID IN AIR(CABLE
kVA / kW VOLTS AMPS SQ.MM BANKS CABLE TRAYS KM %
BANKS TRAY) BANKS TRAY)
(IN BOTH (IN
FLAT/TREFOIL BOTH FLAT/TREFOIL
IN DUCT IN AIR IN FLAT IN TREFOIL IN FLAT IN TREFOIL IN FLAT IN TREFOIL IN FLAT IN TREFOIL
FORMATION) FORMATION)
BANKS FORMATION FORMATION FORMATION FORMATION FORMATION FORMATION FORMATION FORMATION

CASE-1
3 RUNS OF 2 RUNS OF
STATION TRANSFORMER T401 or
1C X 1C X
1 T402 TO STATION SWITCHGEAR 7500 4160 1040.93 665.00 720.00 980.00 960.00 0.6256 0.7654 416.02 450.43 750.09 734.78 0.05 0.109
630 sqmm / 630 sqmm /
INCOMING BREAKERS (Load in
phase phase
kVA)

CASE-2 I RUN OF I RUN OF

STATION SWITCHGEAR TO LV 1C X 630 1C X 630
2 3000 4160 416.37 665.00 720.00 980.00 960.00 0.6256 0.7654 416.02 450.43 750.09 734.78 0.075 0.131
STATION AUX TRANSFORMER sqmm / sqmm /
T201or T202 (Load in kVA) phase phase

CASE-3
for starting = 0.85
STATION SWITCHGEAR TO 1 RUN OF 1 RUN OF
3 596.8 4160 102.58 380.00 410.00 0.7364 0.6230 279.83 255.43 0.2 for running
STARTING MOTORS GT#7 or 3C X 185 3C X 185
= 0.21
GT#8 (Load in kW)

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