8400 – MISC – 005 2

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TITLE

VOLTAGE DROP CALCULATIONS

PROJECT

525 MTPD METHANOL PROJECT

OWNER

M/S GUJARAT STATE FERTILIZERS & CHEMICALS LIMITED

VADODARA

INDIAN ENGINEERING CONSULTANT (IEC)

M/S PROJECTS & DEVELOPMENT INDIA LIMITED

WESTERN REGIONAL OFFICE, VADODARA

2 17.12.2009 17.12.2009 GENERAL REVISION VP VS AGP

1 20.10.2009 20.10.2009 GENERAL REVISION VP VS AGP
0 06.03.2009 06.03.2009 FIRST ISSUE VS VS AGP
REV REV DATE EFF DATE PURPOSE PREPD REVWD APPD
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CONTENTS

SL.
CONTENTS SHEET NO.
NO.

1.0 PURPOSE 3

2.0 CALCULATION 3

2.1 Calculation Basis 3

2.2 Formulas Used 3

3.0 RESULTS 3

4.0 ANNEXURE – 1 4

Calculation sheets for Voltage Drop Calculation for 3.3 kV System

5.0 ANNEXURE – 2 6

Calculation sheets for Voltage Drop Calculation for 415 V System

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1.0 PURPOSE

The purpose of this document is to define the basis for the VOLTAGE DROP CALCULATIONS for 525 MTPD
METHANOL PROJECT at Gujarat State Fertilizers and Chemicals Ltd. (GSFC), VADODARA.

2.0 CALCULATION

2.1 CALCULATION BASIS

The calculations are based on the requirements specified in following documents : -

A) Design Basis for Cable Size Selection (PDIL Doc. No. 8400 – MISC – 003).

B) Power Transformer Sizing Calculations (PDIL Doc. No. 8400 – MISC – 004, Rev-3).

C) Electrical Consumer List (PDIL Doc. No. 8400-0000-0987, Rev-1).

D) Preliminary Load Schedule Power (Electrical Load List) (HTAS Doc. No. 4307449, Rev.-2).

E) Control, Monitoring and Protection Diagram for Power Distribution System (HTAS Doc. No. 0307907, Rev.-3).

F) Single line power distribution diagram for 11 kV, 3.3 kV HT. BD. with RCP (PDIL Doc. No. 8400-0000-0982A,
Rev-2).
G) Single line power distribution diagram for MV switchboards (PDIL Doc. No. 8400-0000-0982B, Rev-0).

2.2 FORMULAS USED

A) IMPEDANCE OF CABLE (Z) = (R + jX) x L (Length of cable in km)

No. of cable runs

B) TOTAL VOLTAGE DROP VT = Drop in the power transformer due to rest load + Drop in the power
transformer due to starting of largest rating motor + Cable drop due to starting of largest rating motor.

C) Total Voltage Drop VT in 3 – phase = „3 x VT

D) % Drop in power transformer due to starting of largest motor is given by :-
VT = Total Voltage Drop VT in 3 – phase x 100
No Load Voltage
E) REST LOAD = Power transformer kVA rating – Largest motor kVA rating

Refer Annexure – 1 & 2 for voltage drop calculations for the 3.3 kV and 415 V System.

3.0 RESULTS
Summary Table for voltage drop calculations are given below.

Voltage System Largest Rating Motor Voltage Drop

3.3 kV System 425 kW (Air Compressor Motor) 11.35 %

415 V System 110 kW (AK-103A/B – Existing Combustion Air Blower Motor) 12.17 %

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ANNEXURE – 1

VOLTAGE DROP CALCULATION FOR 3.3 kV SYSTEM

Let, BASE VALUES ARE

⇒ MVAb = 3.15
Power Transformer ⇒ kVb = 3.3
∆ 3.15 MVA
11 / 3.45 kV
Y
%Z = 6.25%

Cable Size:- 2 – 3c x 300 Sq.mm (Al.),

3.3 kV (UE) Grade, XLPE Insulated
3.3 kV Bus Aluminum Conductor Cable

Cable Size:- 1 – 3c x 150 Sq.mm (Al.),

3.3 kV (UE) Grade, XLPE Insulated
Aluminum Conductor Cable

REST LARGEST RATING MOTOR

LOAD M
425 kW (Air Compressor Motor)

Motor Data: - Taken from Power Transformer Sizing Calculation (8400-MISC-004, Rev-3)
Rating = 425 kW, Power factor = 0.73, Efficiency = 93.5% and Full load current (FLC) = 109 Amps.
Starting Current (ISTARTING) = 4.5 x FLC = 490.5 Amps at p.f. = 0.2.

(ISTARTING) = 490.5 x (0.2 – j 0.98) = 98.1 – j 480.7 Amps.

REST LOAD = 3150 – 622.67 kVA (Taken from Power transformer sizing calculation doc. no. 8400-MISC-004, Rev3)
= 2527.33 kVA
Current at rest load = kVA / (√3 x kV) = 442.17 Amps at 0.9 pf.

ITOTAL = 442.17 (0.9 – j 0.436) Amps.

ITOTAL = 397.95 – j 192.8 Amps.

1) Power transformer Impedance in Ohm (ZTR) = % Z x (kVb)2 = j 0.27225

100 x MVAb

Drop in power transformer due to rest load = ITOTAL x ZTR = 52.5 + j 108.34 ----------------- (1)

2) Drop in power transformer due to starting of largest rating motor (425 kW)
= ISTARTING x ZTR = (98.1 – j 480.7) x j 0.27225 = 130.87 + j 26.71 ----------------- (2)

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3) Cable size from power transformer to 3.3 kV switchboard = 2 – 3c x 300 mm2 (Al.), XLPE Cable
R = 0.1220 ohm/ph./km Data taken From Unistar Cable
Catalogue (Page-19)
X = 0.0730 ohm/ph./km

Length of Cable (L) = 40 m

ZC1 = (R + j X) x L = 0.00244 + j 0.00146

No. of Cable Runs

4) Cable size from 3.3 kV switchboard to the largest rating motor (425 kW) = 1 – 3c x 150 mm2 (Al.), XLPE Cable

R = 0.2513 ohm/ph./km Data taken From Unistar Cable

Catalogue (Page-19)
X = 0.0770 ohm/ph./km

Length of Cable (L) = 160 m

ZC2 = (R + j X) x L = 0.04021 + j 0.01232
No. of Cable Runs

Total Cable Impedance = ZCT = ZC1 + ZC2 = 0.04326 + j 0.0138

So, Cable drop due to starting of largest rating motor

= ISTARTING x ZCT = (98.1 – j 480.7) x (0.04326 + j 0.0138)
= 10.808 – j 19.15 ----------------- (3)

Now,
TOTAL VOLTAGE DROP (VT)
VT = Drop in the power transformer due to rest load
+ Drop in the power transformer due to starting of largest rating motor (425 kW)
+ Cable drop due to starting of largest rating motor.

VT = Eq. (1)
+ Eq. (2)
+ Eq. (3)

VT = 194.18 + j 115.9
VT = 226.14 volt per phase.

Total Voltage Drop VT in 3 – phase = „3 x VT = 391.7 volts

So, % DROP VT = Total Voltage Drop VT in 3 – phase x 100 = 391.7 x 100 = 11.35
No Load Voltage 3450

% DROP IN TRANSFORMER DUE TO STARTING OF LARGEST RATING MOTOR (VT) = 11.35 %

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ANNEXURE – 2

VOLTAGE DROP CALCULATION FOR 415 VOLTS SYSTEM

Let, BASE VALUES ARE

⇒ MVAb = 2
Power Transformer ⇒ kVb = 0.415
∆ 2 MVA
11 / 0.433 kV
Y
%Z = 6.25%

Bus Duct of 3200 Amp Rating

Cable Size:- 2 – 3c x 240 Sq.mm (Al.),

1.1 kV Grade, XLPE Insulated
Aluminum Conductor Cable

REST
LOAD M

LARGEST RATING MOTOR

110 kW (AK-103A/B – Existing Combustion Air Blower Motor)

Motor Data: - Taken from Power Transformer Sizing Calculation (8400-MISC-004, Rev-3)

Rating = 110 kW, Power factor = 0.79, Efficiency = 95.2% and Full load current (FLC) = 205 Amps.

Starting Current (ISTARTING) = 6 x FLC = 1230 Amps at power factor = 0.2.

(ISTARTING) = 1230 x (0.2 – j 0.98) = 246 – j 1205.4 Amps.

REST LOAD = 2000 – 147.5 kVA (Taken from Power transformer sizing calculation doc. no. 8400-MISC-004, Rev-3)
= 1852.5 kVA

Current at rest load = kVA / (√3 x kV) = 2577.21 Amps at 0.9 pf.

ITOTAL = 2577.21 (0.9 – j 0.436) Amps.

ITOTAL = 2319.5 – j 1123.66 Amps.

1) Power transformer Impedance in Ohm (ZTR) = % Z x (kVb)2 = j 0.00538

100 x MVAb

Drop in power transformer due to rest load = ITOTAL x ZTR = 6.045 + j 12.48 ----------------- (4)

2) Drop in power transformer due to starting of largest rating motor (110 kW)

= ISTARTING x ZTR = (246 – j 1205.4) x j 0.00538 = 6.485 + j 1.3235 ----------------- (5)

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3) Considering busduct from power transformer to 0.415 kV switchboard So, voltage drop due to busduct is
negligible.
Therefore, ZC1 = 0

4) Cable size from 0.415 kV switchboard to the largest rating motor = 2 – 3c x 240mm2 (Al.), XLPE Cable

R = 0.1525 ohm/ph./km Data taken From Unistar Cable

Catalogue (Page-19)
X = 0.0710 ohm/ph./km

Length of Cable (L) = 270 m

ZC2 = (R + j X) x L = 0.0206 + j 0.0096

No. of Cable Runs

Total Cable Impedance = ZCT = ZC1 + ZC2 = 0.0206 + j 0.0096

So, Cable drop due to starting of largest rating motor

= ISTARTING x ZCT = (246 – j 1205.5) x (0.0206 + j 0.0096)
= 16.641 – j 22.468 ----------------- (6)

Now,

TOTAL VOLTAGE DROP (VT)

VT = Drop in the power transformer due to rest load

+ Drop in the power transformer due to starting of largest rating motor (110 kW)
+ Cable drop due to starting of largest rating motor.

VT = Eq. (4)
+ Eq. (5)
+ Eq. (6)

VT = 29.171 – j 8.665
VT = 30.431 volt per phase.

Total Voltage Drop VT in 3 – phase = „3 x VT = 52.71 volts

So, % DROP VT = Total Voltage Drop VT in 3 – phase x 100 = 52.71 x 100 = 12.17
No Load Voltage 433

% DROP IN TRANSFORMER DUE TO STARTING OF LARGEST RATING MOTOR (VT) ≈ 12.17 %

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