STF-G-011(REV-0)

COVER SHEET

MBE DOCUMENT 2 A357 DC00 3 0007

NO.

MBE PROJECT NO. A357

CABLE SIZING CALCULATION FOR LT POWER

TITLE
CABLE

PROJECT Ash Handling System for 2x600 MW SALAYA

Thermal Power Plant

CLIENT Essar Power GUJARAT Limited

Essar Engineering Service Limited, Hazira

CONSULTANTS

TCE Consulting Engineers Limited, Bangalore

TOTAL NO. OF
SHTS. REV. DATE PREPARED APPROVED
(EXCLUDING NO. NAME SIGN NAME SIGN
COVER SHEET)
17 0 31/08/09 S. DAS S.K.S

17 1 13/09/09 S. DAS S.K.S

18 2 02/12/09 S. DAS S.K.S

18 3 31/12/09 S. DAS S.K.S

19 4 16/02/10 S. DAS S.K.S

18 5 17/04/10 S. DAS S.K.S

Mcnally Bharat
Engineering Company Limited
PROJECTS DIVISION 4, Mangoe Lane, Kolkata, India
THIS DOCUMENT IS MBE’S PROPERTY AND MUST NOT BE USED
EXCEPT IN CONNECTION WITH MBE’S WORK. USE OR DISCLOSURE
OF THE CONTENTS OF THIS DOCUMENT TO THIRD PARTY/IES
WITHOUT EXPRESS/WRITTEN PERMISSION OF MBE IS STRICTLY
PROHIBITED.
 MBE REPLY

Sr. No. EESL / TCE(VDT-570-92) COMMENTS DATED 15.03.10 MBE REPLY

* CABLE SIZING CALCULATION FOR LT POWER CABLE (2-A357-DC00-3-0007 (Rev.04))
1 Feeder rating for "Bottom Ash Overflow Drain Sump Pump-D" shall be considered as 22kW. 22KW is already indicated.
Cable size for Intermediate Silo Aeration Blower shall be revised to 50 Sqmm as voltage drop is exceeding 3%, Pls check and
2 Revised accordingly.
correct the cable size accordingly.
Cable sizing for the following feeders to be provided. (Feeders considered in LT MCC at ESP bldg)
i) Bottom Ash Local Panel Supply-1 for U#1-32A.
ii) Bottom Ash Local Panel Supply-2 for U#1-32A. Cable sizing for above aux. supply is not
iii) Bottom Ash Local Panel Supply-1 for U#2-32A. required. Cable size shown in "BOQ OF LT
iv) Bottom Ash Local Panel Supply-2 for U#2-32A. POWER CABLES" is sufficient to cater the
3 v) Aux Supply-1 to HCSD Control Panel-32A. aux. loads. The cable size required for
vi) Aux Supply-2 to HCSD Control Panel-32A. "aux supply for ash handling purpose"
vii) Aux supply-1 for Ash Handling purpose-63A. shall be shown as per requirement in
viii) Aux supply-2 for Ash Handling purpose-32A. future.
ix) Aux supply-3 for Ash Handling purpose-63A.
x) Aux supply-4 for Ash Handling purpose-32A.
4 Equipment description for "Telescopic Spout-A " shall be corrected to "Telescopic Chute for FA Silo-A" Revised.
5 Equipment description for "Telescopic Spout-B " shall be corrected to "Telescopic Chute for FA Silo-B" Revised.
Motor rating for Vent Fan for FA SIlo-1 & 2 shall be considered as 9.3kW.(As per Load list 9.3kW is considered for Vent Fan for
6 Revised.
FA Silo).
Cable sizing for the following feeders to be provided.(Feeders considered in LT MCC at Silo Area) Cable sizing for above aux. supply is not
i) ACDB required. Cable size shown in "BOQ OF LT
ii) Aux Supply to Silo Control Panel POWER CABLES" is sufficient to cater the
7 iii) Aux supply-1 for Ash Handling purpose-32A. aux. loads. The cable size required for
vi) Aux supply-2 for Ash Handling purpose-32A. "aux supply for ash handling purpose"
v) Aux supply-3 for Ash Handling purpose-32A. shall be shown as per requirement in
vi) Aux supply-4 for Ash Handling purpose-32A. future.
For some of the MCCB feeders, feeder rating is considered as 63A in SLD, but as per Cable Sizing full load current is exceeding
63A, pls correct the feeder ratings in SLD. The feeders are listed below for correcting the feeders rating accordingly in SLD.
As these are intermittent load, load
i) AC System-1(Control Room)
factor of the above loads shall be 0.5. By
ii) AC System-2(HCSCD Power Pack Unit)
considering load factor 0.5, 1 no 63A
iii) 63A Welding receptacle (1 & 2) for Ash water pump house.
8 MCCB feeder is quite capable of feeding 3
iv) 63A Welding receptacle (3 & 4) for Compressor House.
nos 63A welding receptacles. It is
v) 63A Welding receptacle (5 & 6) for HCSD Pump house.
standard practice, even NTPC also follow
vi) 63A Welding receptacle (7, 8 & 9) for Dewatering Bin.
the same philosophy.
vii) 63A Welding receptacle (11 & 12) for Silo Utility Building.
viii) 63A Welding receptacle (13 & 14) for Silo #1 & # 2.
CLIENT : ESSAR POWER GUJARAT LTD TITLE: CABLE SIZING CALCULATION FOR LT POWER CABLE
CONSULTANT : TCE CONSULTING ENGG. LTD DOC NO: 2-A357-DC00-3-0007, REV-5
PROJECT : 2X600 MW THERMAL POWER PLANT AT SALAYA

Basic philosophy for LT Power Cable sizing:

1. All cables are XLPE insulated.

2. Derating factors considered for XLPE cable :

a) for 50 deg ambient temp derating factor = 0.89 (Ref # Table # 14 of RPG CABLES enclosed).
b) Group derating factor (K2) for 3no trays & 9 no cables in 1 tray, touching each other correction factor =0.68 (Refer Table # 20 of RPG CABLES (ASIAN) enclosed)
c) Overall Derating factor for XLPE cable = 0.89 x 0.68 = 0.605

3. Formula used to calculate percentage voltage drop = [1.732 x Full load current x (Resistance x Cosø + Reactance x Sinø ) x Length of cable in Mtr x 100] / [Supply voltage in Volt]

4. Starting current has been considered as 7.2 times of the full load current while calculating voltage drop during starting.

5. Resistance and reactance values for cables have been taken as base temperature of 20 deg. C from Approved cable manufacturer catalogue.
Actual Resistance & reactance values have been considered at 90 deg. C for XLPE cable.

6. Resistance & reactance correction due to temperature variation shall be followed by the follwing formula
Rt = R x {1+ (temp variation x resistivity of the conductor)}
Xt = R x {1+ (temp variation x resistivity of the conductor)}

Resistivity of AL. conductor = 0.00409

Resistivity of Cu. conductor = 0.00393

7. Permissive voltage drop during starting condition, limited to 15% & during running condition, limited to 3% of the rated voltage.
( Refer CL# 3.1.6 OF SECTION: D2.03, SHT 2 0F 6 OF SPEC NO. TCE 52594A-H-570-002)

8. Cable lengths are based on layout drawing and considering the maximum length of similar type/rating
feeders estimated among the no of drives for the same equipment. During detail engineering, any changes take place in
location of equipment, & routing of cables , this shall be incorporated and revised in the cable schedule accordingly.

9. AC Current ratting in air at 40 deg C and Resistance at 20 deg. C of the XLPE cables have been taken from Table no 1,2,3 & 4
of manufacturer M/S RPG CABLES LTD
 CLIENT : ESSAR POWER GUJARAT LTD. TITLE : CABLE SIZING CALCULATION FOR LT POWER CABLE FOR AHP
CONSULTANT : TCE CONSULTING ENGG. LTD. DOC NO: 2-A357-DC00-3-0007, REV-5
PROJECT : 2X600 MW THERMAL POWER PLANT AT SALAYA

Voltage Voltage Voltage Voltage

Derated Effective Actual
Full Load Drop in Drop in Motor Drop in Drop in
Derating Current Type Rated No. of Length "R" of "R" of Resist.of Actual
FDR Efficency Power Rated Full No. Of Type Of Cable Cable Starting Cable Cable
SL NO Equipment Description Sin f1 Factor of for Of Selected current Parallel of Cable at Cable at "X" Cable at React. of Sin f2
Rating (η) Factor Load Current Cores Conductor during during p.f. during during
Cable selection Cables carrying Runs Cable 20 DEG-C 90 DEG-C 90 DEG- Cable
(Cos f1) Running Running (Cos f2) Starting Starting
of Cable capacity C
(VMN) (VMN) (VMS) (VMS)
kW % Amps Amps mm² Amps No. Mtrs. Ohms/km Ohms/km Ohms/km Ohms Ohms Volts % Volts %
A B C D E F G H I J K L M N O P Q R S T U V W X
√(1-E²) G/H Nx(1+70x
(C/(DxE)) x 7.2xGx1.73
Resistivity MxO/ MxP/1000 1.732xGx(
FROM TO (1000/1.732x (S/415)x100 √(1-U²) 2x(QxU+Rx W/415x100
of 1000xL) xL) ExQ+FxR)
415) V)
conductor)

LT MCC AT SWGR
1 HP Water Pump - A 195 0.95 0.865 0.502 330.141 0.6052 545.507 3C XLPE 300.0 AL 798 2 150 0.1 0.129 0.071 0.010 0.005 6.295 1.517 0.3 0.954 32.770 7.896
ROOM IN ESP AREA

LT MCC AT SWGR
2 HP Water Pump - B 195 0.95 0.865 0.502 330.141 0.6052 545.507 3C XLPE 300.0 AL 798 2 150 0.1 0.129 0.071 0.010 0.005 6.295 1.517 0.3 0.954 32.770 7.896
ROOM IN ESP AREA

LT MCC AT SWGR
3 LP Water Pump - A 15 0.905 0.86 0.510 26.813 0.6052 44.305 3C XLPE 35.0 AL 117 1 150 0.868 1.117 0.078 0.167 0.012 6.966 1.679 0.3 0.954 20.532 4.947
ROOM IN ESP AREA

LT MCC AT SWGR
4 LP Water Pump - B 15 0.905 0.86 0.510 26.813 0.6052 44.305 3C XLPE 35.0 AL 117 1 150 0.868 1.117 0.078 0.167 0.012 6.966 1.679 0.3 0.954 20.532 4.947
ROOM IN ESP AREA

LT MCC AT SWGR
5 LP Water Pump - C 15 0.905 0.86 0.510 26.813 0.6052 44.305 3C XLPE 35.0 AL 117 1 150 0.868 1.117 0.078 0.167 0.012 6.966 1.679 0.3 0.954 20.532 4.947
ROOM IN ESP AREA

LT MCC AT SWGR Bottom Ash Overflow Drain Sump

6 22.0 0.905 0.85 0.527 39.789 0.6052 65.745 3C XLPE 35.0 AL 117 1 175 0.868 1.117 0.078 0.195 0.014 11.941 2.877 0.3 0.954 35.545 8.565
ROOM IN ESP AREA Pump-A

LT MCC AT SWGR Bottom Ash Overflow Drain Sump

7 22.0 0.905 0.85 0.527 39.789 0.6052 65.745 3C XLPE 35.0 AL 117 1 175 0.868 1.117 0.078 0.195 0.014 11.941 2.877 0.3 0.954 35.545 8.565
ROOM IN ESP AREA Pump-B

LT MCC AT SWGR Bottom Ash Overflow Drain Sump

8 22.0 0.905 0.85 0.527 39.789 0.6052 65.745 3C XLPE 35.0 AL 117 1 175 0.868 1.117 0.078 0.195 0.014 11.941 2.877 0.3 0.954 35.545 8.565
ROOM IN ESP AREA Pump-C

LT MCC AT SWGR Bottom Ash Overflow Drain Sump

9 22.0 0.905 0.85 0.527 39.789 0.6052 65.745 3C XLPE 35.0 AL 117 1 175 0.868 1.117 0.078 0.195 0.014 11.941 2.877 0.3 0.954 35.545 8.565
ROOM IN ESP AREA Pump-D

LT MCC AT SWGR Fly Ash Conditioner Water Pump -

10 55 0.93 0.87 0.493 94.572 0.6052 156.266 3C XLPE 95.0 AL 221 1 150 0.32 0.412 0.073 0.062 0.011 9.677 2.332 0.3 0.954 34.080 8.212
ROOM IN ESP AREA A

LT MCC AT SWGR Fly Ash Conditioner Water Pump -

11 55 0.93 0.87 0.493 94.572 0.6052 156.266 3C XLPE 95.0 AL 221 1 150 0.32 0.412 0.073 0.062 0.011 9.677 2.332 0.3 0.954 34.080 8.212
ROOM IN ESP AREA B

LT MCC AT SWGR
12 Clinker Grinder - 1A 11 0.87 0.79 0.613 22.266 0.6052 36.792 3C XLPE 25.0 AL 96 1 175 1.2 1.544 0.081 0.270 0.014 8.564 2.064 0.3 0.954 26.247 6.325
ROOM IN ESP AREA

LT MCC AT SWGR
13 Clinker Grinder - 1B 11 0.87 0.79 0.613 22.266 0.6052 36.792 3C XLPE 25.0 AL 96 1 175 1.2 1.544 0.081 0.270 0.014 8.564 2.064 0.3 0.954 26.247 6.325
ROOM IN ESP AREA

LT MCC AT SWGR
14 Clinker Grinder - 2A 11 0.87 0.79 0.613 22.266 0.6052 36.792 3C XLPE 25.0 AL 96 1 175 1.2 1.544 0.081 0.270 0.014 8.564 2.064 0.3 0.954 26.247 6.325
ROOM IN ESP AREA

LT MCC AT SWGR
15 Clinker Grinder - 2B 11 0.87 0.79 0.613 22.266 0.6052 36.792 3C XLPE 25.0 AL 96 1 175 1.2 1.544 0.081 0.270 0.014 8.564 2.064 0.3 0.954 26.247 6.325
ROOM IN ESP AREA

LT MCC AT SWGR
16 Clinker Grinder for HCSD System 11 0.87 0.79 0.613 22.266 0.6052 36.792 3C XLPE 25.0 AL 96 1 175 1.2 1.544 0.081 0.270 0.014 8.564 2.064 0.3 0.954 26.247 6.325
ROOM IN ESP AREA
Reciprocating Feeder-A (with
LT MCC AT SWGR
17 frequency controller) below 1.5 0.76 0.79 0.613 3.476 0.6052 5.743 4C XLPE 10.0 AL 50 1 170 3.08 3.962 0.084 0.674 0.014 3.256 0.785 0.3 0.954 9.348 2.253
ROOM IN ESP AREA
Dewatering Bin
Reciprocating Feeder-B (with
LT MCC AT SWGR
18 frequency controller) below 1.5 0.76 0.79 0.613 3.476 0.6052 5.743 4C XLPE 10.0 AL 50 1 170 3.08 3.962 0.084 0.674 0.014 3.256 0.785 0.3 0.954 9.348 2.253
ROOM IN ESP AREA
Dewatering Bin
Reciprocating Feeder-C (with
LT MCC AT SWGR
19 frequency controller) below 1.5 0.76 0.79 0.613 3.476 0.6052 5.743 4C XLPE 10.0 AL 50 1 170 3.08 3.962 0.084 0.674 0.014 3.256 0.785 0.3 0.954 9.348 2.253
ROOM IN ESP AREA
Dewatering Bin

LT MCC AT SWGR
20 Bin Vibrator- A for Dewatering Bin 3.5 0.83 0.82 0.572 7.155 0.6052 11.822 4C XLPE 10.0 AL 50 1 170 3.08 3.962 0.084 0.674 0.014 6.945 1.673 0.3 0.954 19.242 4.637
ROOM IN ESP AREA

LT MCC AT SWGR
21 Bin Vibrator- B for Dewatering Bin 3.5 0.83 0.82 0.572 7.155 0.6052 11.822 4C XLPE 10.0 AL 50 1 170 3.08 3.962 0.084 0.674 0.014 6.945 1.673 0.3 0.954 19.242 4.637
ROOM IN ESP AREA

1 OF 6
 CLIENT : ESSAR POWER GUJARAT LTD. TITLE : CABLE SIZING CALCULATION FOR LT POWER CABLE FOR AHP
CONSULTANT : TCE CONSULTING ENGG. LTD. DOC NO: 2-A357-DC00-3-0007, REV-5
PROJECT : 2X600 MW THERMAL POWER PLANT AT SALAYA

Voltage Voltage Voltage Voltage

Derated Effective Actual
Full Load Drop in Drop in Motor Drop in Drop in
Derating Current Type Rated No. of Length "R" of "R" of Resist.of Actual
FDR Efficency Power Rated Full No. Of Type Of Cable Cable Starting Cable Cable
SL NO Equipment Description Sin f1 Factor of for Of Selected current Parallel of Cable at Cable at "X" Cable at React. of Sin f2
Rating (η) Factor Load Current Cores Conductor during during p.f. during during
Cable selection Cables carrying Runs Cable 20 DEG-C 90 DEG-C 90 DEG- Cable
(Cos f1) Running Running (Cos f2) Starting Starting
of Cable capacity C
(VMN) (VMN) (VMS) (VMS)
kW % Amps Amps mm² Amps No. Mtrs. Ohms/km Ohms/km Ohms/km Ohms Ohms Volts % Volts %
A B C D E F G H I J K L M N O P Q R S T U V W X
√(1-E²) G/H Nx(1+70x
(C/(DxE)) x 7.2xGx1.73
Resistivity MxO/ MxP/1000 1.732xGx(
FROM TO (1000/1.732x (S/415)x100 √(1-U²) 2x(QxU+Rx W/415x100
of 1000xL) xL) ExQ+FxR)
415) V)
conductor)

LT MCC AT SWGR
22 Bin Vibrator- C for Dewatering Bin 3.5 0.83 0.82 0.572 7.155 0.6052 11.822 4C XLPE 10.0 AL 50 1 170 3.08 3.962 0.084 0.674 0.014 6.945 1.673 0.3 0.954 19.242 4.637
ROOM IN ESP AREA

LT MCC AT SWGR
23 Bin Vibrator- D for Dewatering Bin 3.5 0.83 0.82 0.572 7.155 0.6052 11.822 4C XLPE 10.0 AL 50 1 170 3.08 3.962 0.084 0.674 0.014 6.945 1.673 0.3 0.954 19.242 4.637
ROOM IN ESP AREA

LT MCC AT SWGR
24 Bin Vibrator- E for Dewatering Bin 3.5 0.83 0.82 0.572 7.155 0.6052 11.822 4C XLPE 10.0 AL 50 1 170 3.08 3.962 0.084 0.674 0.014 6.945 1.673 0.3 0.954 19.242 4.637
ROOM IN ESP AREA

LT MCC AT SWGR
25 Bin Vibrator- F for Dewatering Bin 3.5 0.83 0.82 0.572 7.155 0.6052 11.822 4C XLPE 10.0 AL 50 1 170 3.08 3.962 0.084 0.674 0.014 6.945 1.673 0.3 0.954 19.242 4.637
ROOM IN ESP AREA

LT MCC AT SWGR
26 Bin Vibrator- G for Dewatering Bin 3.5 0.83 0.82 0.572 7.155 0.6052 11.822 4C XLPE 10.0 AL 50 1 170 3.08 3.962 0.084 0.674 0.014 6.945 1.673 0.3 0.954 19.242 4.637
ROOM IN ESP AREA

LT MCC AT SWGR
27 Bin Vibrator- H for Dewatering Bin 3.5 0.83 0.82 0.572 7.155 0.6052 11.822 4C XLPE 10.0 AL 50 1 170 3.08 3.962 0.084 0.674 0.014 6.945 1.673 0.3 0.954 19.242 4.637
ROOM IN ESP AREA

LT MCC AT SWGR
28 Bin Vibrator- I for Dewatering Bin 3.5 0.83 0.82 0.572 7.155 0.6052 11.822 4C XLPE 10.0 AL 50 1 170 3.08 3.962 0.084 0.674 0.014 6.945 1.673 0.3 0.954 19.242 4.637
ROOM IN ESP AREA

LT MCC AT SWGR
29 Belt Conveyor 7.5 0.86 0.83 0.558 14.618 0.6052 24.154 3C XLPE 16.0 AL 64 1 180 1.91 2.457 0.080 0.442 0.014 9.496 2.288 0.3 0.954 26.682 6.429
ROOM IN ESP AREA

LT MCC AT SWGR Intermediate Silo Aeration Blower -

30 22 0.91 0.87 0.493 38.660 0.6052 63.880 3C XLPE 50.0 AL 117 1 190 0.641 0.825 0.075 0.157 0.014 9.598 2.313 0.3 0.954 29.229 7.043
ROOM IN ESP AREA A
LT MCC AT SWGR Intermediate Silo Aeration Blower -
31 22 0.91 0.87 0.493 38.660 0.6052 63.880 3C XLPE 50.0 AL 117 1 190 0.641 0.825 0.075 0.157 0.014 9.598 2.313 0.3 0.954 29.229 7.043
ROOM IN ESP AREA B
LT MCC AT SWGR Intermediate Silo Aeration Blower -
32 22 0.91 0.87 0.493 38.660 0.6052 63.880 3C XLPE 50.0 AL 117 1 190 0.641 0.825 0.075 0.157 0.014 9.598 2.313 0.3 0.954 29.229 7.043
ROOM IN ESP AREA C

LT MCC AT SWGR Heater-A for Intermediate Silo

33 18 0.9 0.86 0.510 32.355 0.6052 53.461 4C XLPE 35.0 AL 117 1 190 0.868 1.117 0.078 0.212 0.015 10.647 2.566 0.3 0.954 31.382 7.562
ROOM IN ESP AREA Blower

LT MCC AT SWGR Heater-B for Intermediate Silo

34 18 0.9 0.86 0.510 32.355 0.6052 53.461 4C XLPE 35.0 AL 117 1 190 0.868 1.117 0.078 0.212 0.015 10.647 2.566 0.3 0.954 31.382 7.562
ROOM IN ESP AREA Blower

LT MCC AT SWGR Heater-C for Intermediate Silo

35 18 0.9 0.86 0.510 32.355 0.6052 53.461 4C XLPE 35.0 AL 117 1 190 0.868 1.117 0.078 0.212 0.015 10.647 2.566 0.3 0.954 31.382 7.562
ROOM IN ESP AREA Blower

LT MCC AT SWGR
36 Conveying Air Compressor - A 195 0.95 0.865 0.502 330.141 0.6052 545.507 3C XLPE 300.0 AL 798 2 225 0.1 0.129 0.071 0.014 0.008 9.443 2.275 0.3 0.954 49.154 11.844
ROOM IN ESP AREA

LT MCC AT SWGR
37 Conveying Air Compressor - B 195 0.95 0.865 0.502 330.141 0.6052 545.507 3C XLPE 300.0 AL 798 2 220 0.1 0.129 0.071 0.014 0.008 9.233 2.225 0.3 0.954 48.062 11.581
ROOM IN ESP AREA

LT MCC AT SWGR
38 Conveying Air Compressor - C 195 0.95 0.865 0.502 330.141 0.6052 545.507 3C XLPE 300.0 AL 798 2 215 0.1 0.129 0.071 0.014 0.008 9.023 2.174 0.3 0.954 46.970 11.318
ROOM IN ESP AREA

LT MCC AT SWGR
39 Conveying Air Compressor - D 195 0.95 0.865 0.502 330.141 0.6052 545.507 3C XLPE 300.0 AL 798 2 210 0.1 0.129 0.071 0.014 0.007 8.813 2.124 0.3 0.954 45.877 11.055
ROOM IN ESP AREA

LT MCC AT SWGR
40 Conveying Air Compressor - E 195 0.95 0.865 0.502 330.141 0.6052 545.507 3C XLPE 300.0 AL 798 2 205 0.1 0.129 0.071 0.013 0.007 8.603 2.073 0.3 0.954 44.785 10.792
ROOM IN ESP AREA

LT MCC AT SWGR
41 Conveying Air Compressor - F 195 0.95 0.865 0.502 330.141 0.6052 545.507 3C XLPE 300.0 AL 798 2 200 0.1 0.129 0.071 0.013 0.007 8.394 2.023 0.3 0.954 43.693 10.528
ROOM IN ESP AREA

2 OF 6
 CLIENT : ESSAR POWER GUJARAT LTD. TITLE : CABLE SIZING CALCULATION FOR LT POWER CABLE FOR AHP
CONSULTANT : TCE CONSULTING ENGG. LTD. DOC NO: 2-A357-DC00-3-0007, REV-5
PROJECT : 2X600 MW THERMAL POWER PLANT AT SALAYA

Voltage Voltage Voltage Voltage

Derated Effective Actual
Full Load Drop in Drop in Motor Drop in Drop in
Derating Current Type Rated No. of Length "R" of "R" of Resist.of Actual
FDR Efficency Power Rated Full No. Of Type Of Cable Cable Starting Cable Cable
SL NO Equipment Description Sin f1 Factor of for Of Selected current Parallel of Cable at Cable at "X" Cable at React. of Sin f2
Rating (η) Factor Load Current Cores Conductor during during p.f. during during
Cable selection Cables carrying Runs Cable 20 DEG-C 90 DEG-C 90 DEG- Cable
(Cos f1) Running Running (Cos f2) Starting Starting
of Cable capacity C
(VMN) (VMN) (VMS) (VMS)
kW % Amps Amps mm² Amps No. Mtrs. Ohms/km Ohms/km Ohms/km Ohms Ohms Volts % Volts %
A B C D E F G H I J K L M N O P Q R S T U V W X
√(1-E²) G/H Nx(1+70x
(C/(DxE)) x 7.2xGx1.73
Resistivity MxO/ MxP/1000 1.732xGx(
FROM TO (1000/1.732x (S/415)x100 √(1-U²) 2x(QxU+Rx W/415x100
of 1000xL) xL) ExQ+FxR)
415) V)
conductor)

LT MCC AT SWGR Air Drying Plant- A for Conveying

42 9.3 0.86 0.83 0.558 18.126 0.6052 29.951 4C XLPE 25.0 AL 96 1 225 1.2 1.544 0.081 0.347 0.018 9.368 2.257 0.3 0.954 27.472 6.620
ROOM IN ESP AREA air compressor (Refrigerant type)

LT MCC AT SWGR Air Drying Plant- B for Conveying

43 9.3 0.86 0.83 0.558 18.126 0.6052 29.951 4C XLPE 25.0 AL 96 1 220 1.2 1.544 0.081 0.340 0.018 9.160 2.207 0.3 0.954 26.861 6.473
ROOM IN ESP AREA air compressor (Refrigerant type)

LT MCC AT SWGR Air Drying Plant- C for Conveying

44 9.3 0.86 0.83 0.558 18.126 0.6052 29.951 4C XLPE 25.0 AL 96 1 215 1.2 1.544 0.081 0.332 0.017 8.952 2.157 0.3 0.954 26.251 6.325
ROOM IN ESP AREA air compressor (Refrigerant type)

LT MCC AT SWGR Air Drying Plant- D for Conveying

45 9.3 0.86 0.83 0.558 18.126 0.6052 29.951 4C XLPE 25.0 AL 96 1 210 1.2 1.544 0.081 0.324 0.017 8.744 2.107 0.3 0.954 25.640 6.178
ROOM IN ESP AREA air compressor (Refrigerant type)

LT MCC AT SWGR Air Drying Plant- E for Conveying

46 9.3 0.86 0.83 0.558 18.126 0.6052 29.951 4C XLPE 25.0 AL 96 1 205 1.2 1.544 0.081 0.316 0.017 8.535 2.057 0.3 0.954 25.030 6.031
ROOM IN ESP AREA air compressor (Refrigerant type)

LT MCC AT SWGR Air Drying Plant- F for Conveying

47 9.3 0.86 0.83 0.558 18.126 0.6052 29.951 4C XLPE 25.0 AL 96 1 200 1.2 1.544 0.081 0.309 0.016 8.327 2.007 0.3 0.954 24.419 5.884
ROOM IN ESP AREA air compressor (Refrigerant type)

LT MCC AT SILO
48 Silo Aeration Blower-A 37 0.925 0.86 0.510 64.709 0.6052 106.922 3C XLPE 50.0 AL 142 1 60 0.641 0.825 0.075 0.049 0.005 5.026 1.211 0.3 0.954 15.449 3.723
AREA
LT MCC AT SILO
49 Silo Aeration Blower-B 37 0.925 0.86 0.510 64.709 0.6052 106.922 3C XLPE 50.0 AL 142 1 60 0.641 0.825 0.075 0.049 0.005 5.026 1.211 0.3 0.954 15.449 3.723
AREA
LT MCC AT SILO
50 Silo Aeration Blower-C 37 0.925 0.86 0.510 64.709 0.6052 106.922 3C XLPE 50.0 AL 142 1 60 0.641 0.825 0.075 0.049 0.005 5.026 1.211 0.3 0.954 15.449 3.723
AREA
LT MCC AT SILO
51 Heater -A for silo areation blower 27 0.91 0.87 0.493 47.447 0.6052 78.399 4C XLPE 25.0 AL 96 1 60 1.2 1.544 0.081 0.093 0.005 6.818 1.643 0.3 0.954 19.176 4.621
AREA
LT MCC AT SILO
52 Heater -B for silo areation blower 27 0.91 0.87 0.493 47.447 0.6052 78.399 4C XLPE 25.0 AL 96 1 60 1.2 1.544 0.081 0.093 0.005 6.818 1.643 0.3 0.954 19.176 4.621
AREA
LT MCC AT SILO
53 Heater -C for silo areation blower 27 0.91 0.87 0.493 47.447 0.6052 78.399 4C XLPE 25.0 AL 96 1 60 1.2 1.544 0.081 0.093 0.005 6.818 1.643 0.3 0.954 19.176 4.621
AREA
LT MCC AT SWGR Sludge Pump- A below Settling
54 9.3 0.86 0.83 0.558 18.126 0.6052 29.951 3C XLPE 16.0 AL 64 1 165 1.91 2.457 0.080 0.405 0.013 10.794 2.601 0.3 0.954 30.329 7.308
ROOM IN ESP AREA Tank

LT MCC AT SWGR Sludge Pump- B below Settling

55 9.3 0.86 0.83 0.558 18.126 0.6052 29.951 3C XLPE 16.0 AL 64 1 165 1.91 2.457 0.080 0.405 0.013 10.794 2.601 0.3 0.954 30.329 7.308
ROOM IN ESP AREA Tank
LT MCC AT SWGR Drain Sump Pump - A (Ash
56 11 0.885 0.86 0.510 20.107 0.6052 33.224 3C XLPE 16.0 AL 64 1 160 1.91 2.457 0.080 0.393 0.013 12.000 2.892 0.3 0.954 32.624 7.861
ROOM IN ESP AREA Handling Plant Complex Area)
LT MCC AT SWGR Drain Sump Pump - B (Ash
57 11 0.885 0.86 0.510 20.107 0.6052 33.224 3C XLPE 16.0 AL 64 1 160 1.91 2.457 0.080 0.393 0.013 12.000 2.892 0.3 0.954 32.624 7.861
ROOM IN ESP AREA Handling Plant Complex Area)

LT MCC AT SILO
58 Drain Sump Pump- A (Silo Area) 5.5 0.85 0.83 0.558 10.846 0.6052 17.921 3C XLPE 16.0 AL 64 1 60 1.91 2.457 0.080 0.147 0.005 2.349 0.566 0.3 0.954 6.599 1.590
AREA

LT MCC AT SILO
59 Drain Sump Pump- B (Silo Area) 5.5 0.85 0.83 0.558 10.846 0.6052 17.921 3C XLPE 16.0 AL 64 1 60 1.91 2.457 0.080 0.147 0.005 2.349 0.566 0.3 0.954 6.599 1.590
AREA

LT MCC AT SILO
60 Dust Conditioner-A (Rotary Type) 11 0.885 0.86 0.510 20.107 0.6052 33.224 3C XLPE 16.0 AL 64 1 75 1.91 2.457 0.080 0.184 0.006 5.625 1.355 0.3 0.954 15.293 3.685
AREA

LT MCC AT SILO
61 Dust Conditioner-B (Rotary Type) 11 0.885 0.86 0.510 20.107 0.6052 33.224 3C XLPE 16.0 AL 64 1 75 1.91 2.457 0.080 0.184 0.006 5.625 1.355 0.3 0.954 15.293 3.685
AREA

3 OF 6
 CLIENT : ESSAR POWER GUJARAT LTD. TITLE : CABLE SIZING CALCULATION FOR LT POWER CABLE FOR AHP
CONSULTANT : TCE CONSULTING ENGG. LTD. DOC NO: 2-A357-DC00-3-0007, REV-5
PROJECT : 2X600 MW THERMAL POWER PLANT AT SALAYA

Voltage Voltage Voltage Voltage

Derated Effective Actual
Full Load Drop in Drop in Motor Drop in Drop in
Derating Current Type Rated No. of Length "R" of "R" of Resist.of Actual
FDR Efficency Power Rated Full No. Of Type Of Cable Cable Starting Cable Cable
SL NO Equipment Description Sin f1 Factor of for Of Selected current Parallel of Cable at Cable at "X" Cable at React. of Sin f2
Rating (η) Factor Load Current Cores Conductor during during p.f. during during
Cable selection Cables carrying Runs Cable 20 DEG-C 90 DEG-C 90 DEG- Cable
(Cos f1) Running Running (Cos f2) Starting Starting
of Cable capacity C
(VMN) (VMN) (VMS) (VMS)
kW % Amps Amps mm² Amps No. Mtrs. Ohms/km Ohms/km Ohms/km Ohms Ohms Volts % Volts %
A B C D E F G H I J K L M N O P Q R S T U V W X
√(1-E²) G/H Nx(1+70x
(C/(DxE)) x 7.2xGx1.73
Resistivity MxO/ MxP/1000 1.732xGx(
FROM TO (1000/1.732x (S/415)x100 √(1-U²) 2x(QxU+Rx W/415x100
of 1000xL) xL) ExQ+FxR)
415) V)
conductor)
LT MCC AT SILO
62 Telescopic Chute - A for FA Silo 2.2 0.8 0.82 0.572 4.666 0.6052 7.709 3C XLPE 2.5 CU 43 1 110 7.41 9.448 0.099 1.039 0.011 6.938 1.672 0.3 0.954 18.746 4.517
AREA
LT MCC AT SILO
63 Telescopic Chute - B for FA Silo 2.2 0.8 0.82 0.572 4.666 0.6052 7.709 3C XLPE 2.5 CU 43 1 120 7.41 9.448 0.099 1.134 0.012 7.568 1.824 0.3 0.954 20.450 4.928
AREA
LT MCC AT SWGR Telescopic Chute for intermediate
64 2.2 0.8 0.82 0.572 4.666 0.6052 7.709 3C XLPE 2.5 CU 43 1 165 7.41 9.448 0.099 1.559 0.016 10.406 2.508 0.3 0.954 28.119 6.776
ROOM IN ESP AREA silo

LT MCC AT SILO
65 Silo vent fan - A 9.3 0.86 0.83 0.558 18.126 0.6052 29.951 3C XLPE 16.0 AL 64 1 120 1.91 2.457 0.080 0.295 0.010 7.850 1.892 0.3 0.954 22.057 5.315
AREA

LT MCC AT SILO
66 Silo vent fan - B 9.3 0.86 0.83 0.558 18.126 0.6052 29.951 3C XLPE 16.0 AL 64 1 130 1.91 2.457 0.080 0.319 0.010 8.504 2.049 0.3 0.954 23.896 5.758
AREA

LT MCC AT SWGR
67 Vent Fan for intermediate silo 11 0.885 0.86 0.510 20.107 0.6052 33.224 3C XLPE 25.0 AL 96 1 180 1.2 1.544 0.081 0.278 0.015 8.580 2.067 0.3 0.954 24.379 5.875
ROOM IN ESP AREA
LT MCC AT SILO
68 Rotary Feeder- A 2.2 0.8 0.82 0.572 4.666 0.6052 7.709 3C XLPE 2.5 CU 43 1 115 7.41 9.448 0.099 1.087 0.011 7.253 1.748 0.3 0.954 19.598 4.722
AREA
LT MCC AT SILO
69 Rotary Feeder- B 2.2 0.8 0.82 0.572 4.666 0.6052 7.709 3C XLPE 2.5 CU 43 1 125 7.41 9.448 0.099 1.181 0.012 7.884 1.900 0.3 0.954 21.303 5.133
AREA
LT MCC AT SWGR Rotary Feeder- C below
70 2.2 0.8 0.82 0.572 4.666 0.6052 7.709 3C XLPE 2.5 CU 43 1 165 7.41 9.448 0.099 1.559 0.016 10.406 2.508 0.3 0.954 28.119 6.776
ROOM IN ESP AREA intermediate silo
LT MCC AT SWGR
71 Measuring Loop Pump 2.2 0.8 0.82 0.572 4.666 0.6052 7.709 3C XLPE 2.5 CU 43 1 155 7.41 9.448 0.099 1.465 0.015 9.776 2.356 0.3 0.954 26.415 6.365
ROOM IN ESP AREA
LT MCC AT SWGR
72 Paddle Mixer for HCSD System 37 0.925 0.86 0.510 64.709 0.6052 106.922 3C XLPE 95.0 AL 221 1 165 0.32 0.412 0.073 0.068 0.012 7.230 1.742 0.3 0.954 25.650 6.181
ROOM IN ESP AREA
LT MCC AT SWGR
73 Agitator for Mixing Tank 75 0.93 0.87 0.493 128.962 0.6052 213.091 3C XLPE 120.0 AL 257 1 165 0.253 0.325 0.071 0.054 0.012 11.730 2.827 0.3 0.954 43.955 10.592
ROOM IN ESP AREA
LT MCC AT SWGR Electricaly operated Under Slung
74 15.5 0.75 0.75 0.661 38.337 0.6052 63.345 4C XLPE 35.0 AL 117 1 200 0.868 1.117 0.078 0.223 0.016 11.806 2.845 0.3 0.954 39.150 9.434
ROOM IN ESP AREA Crane in Compressor House

LT MCC AT SWGR Electricaly operated Under Slung

75 9.7 0.75 0.75 0.661 23.991 0.6052 39.642 4C XLPE 16.0 AL 64 1 150 1.91 2.457 0.080 0.369 0.012 11.814 2.847 0.3 0.954 36.493 8.793
ROOM IN ESP AREA Crane in Ash Water Pump House

LT MCC AT SWGR Electricaly operated Under Slung

76 12.3 0.75 0.75 0.661 30.422 0.6052 50.268 4C XLPE 25.0 AL 96 1 150 1.2 1.544 0.081 0.232 0.012 9.572 2.307 0.3 0.954 30.738 7.407
ROOM IN ESP AREA Crane in HCSD Pump House

LT MCC AT SWGR
77 Electric Hoist over Mixing Tank 4.6 0.75 0.75 0.661 11.377 0.6052 18.799 4C XLPE 16.0 AL 64 1 170 1.91 2.457 0.080 0.418 0.014 6.349 1.530 0.3 0.954 19.613 4.726
ROOM IN ESP AREA
LT MCC AT SWGR Supply for pressurized ventilation
78 37 0.925 0.86 0.510 64.709 0.6052 106.922 3C XLPE 50.0 AL 142 1 100 0.641 0.825 0.075 0.082 0.008 8.377 2.019 0.3 0.954 25.749 6.205
ROOM IN ESP AREA system

LT MCC AT SWGR Power JB for ventilation fan of

79 14.8 0.83 0.82 0.572 30.253 0.6052 49.989 4C XLPE 16.0 AL 64 1 50 1.91 2.457 0.080 0.123 0.004 5.398 1.301 0.3 0.954 15.339 3.696
ROOM IN ESP AREA SWGR / Control Room

4 OF 6
 CLIENT : ESSAR POWER GUJARAT LTD. TITLE : CABLE SIZING CALCULATION FOR LT POWER CABLE FOR AHP
CONSULTANT : TCE CONSULTING ENGG. LTD. DOC NO: 2-A357-DC00-3-0007, REV-5
PROJECT : 2X600 MW THERMAL POWER PLANT AT SALAYA

Voltage Voltage Voltage Voltage

Derated Effective Actual
Full Load Drop in Drop in Motor Drop in Drop in
Derating Current Type Rated No. of Length "R" of "R" of Resist.of Actual
FDR Efficency Power Rated Full No. Of Type Of Cable Cable Starting Cable Cable
SL NO Equipment Description Sin f1 Factor of for Of Selected current Parallel of Cable at Cable at "X" Cable at React. of Sin f2
Rating (η) Factor Load Current Cores Conductor during during p.f. during during
Cable selection Cables carrying Runs Cable 20 DEG-C 90 DEG-C 90 DEG- Cable
(Cos f1) Running Running (Cos f2) Starting Starting
of Cable capacity C
(VMN) (VMN) (VMS) (VMS)
kW % Amps Amps mm² Amps No. Mtrs. Ohms/km Ohms/km Ohms/km Ohms Ohms Volts % Volts %
A B C D E F G H I J K L M N O P Q R S T U V W X
√(1-E²) G/H Nx(1+70x
(C/(DxE)) x 7.2xGx1.73
Resistivity MxO/ MxP/1000 1.732xGx(
FROM TO (1000/1.732x (S/415)x100 √(1-U²) 2x(QxU+Rx W/415x100
of 1000xL) xL) ExQ+FxR)
415) V)
conductor)

LT MCC AT SWGR Power JB for ventilation fan of Ash

80 3 0.75 0.75 0.661 7.420 0.6052 12.260 4C XLPE 10.0 AL 50 1 150 3.08 3.962 0.078 0.594 0.012 5.827 1.404 0.3 0.954 17.528 4.224
ROOM IN ESP AREA Water Pump House

LT MCC AT SWGR Power JB#1 for ventilation fan of

81 4.4 0.75 0.75 0.661 10.883 0.6052 17.982 4C XLPE 10.0 AL 50 1 175 3.08 3.962 0.078 0.693 0.014 9.971 2.403 0.3 0.954 29.992 7.227
ROOM IN ESP AREA Compressor House

LT MCC AT SWGR Power JB#2 for ventilation fan of

82 4.4 0.75 0.75 0.661 10.883 0.6052 17.982 4C XLPE 10.0 AL 50 1 175 3.08 3.962 0.078 0.693 0.014 9.971 2.403 0.3 0.954 29.992 7.227
ROOM IN ESP AREA Compressor House

LT MCC AT SWGR Power JB for ventilation fan of

83 2.2 0.75 0.75 0.661 5.441 0.6052 8.991 4C XLPE 10.0 AL 50 1 150 3.08 3.962 0.078 0.594 0.012 4.273 1.030 0.3 0.954 12.854 3.097
ROOM IN ESP AREA HCSD Pump House

LT MCC AT SILO Power JB for ventilation fan of silo

84 3.3 0.75 0.75 0.661 8.162 0.6052 13.486 4C XLPE 10.0 AL 50 1 80 3.08 3.962 0.078 0.317 0.006 3.419 0.824 0.3 0.954 10.283 2.478
AREA area MCC room

LT MCC AT SILO Power JB for ventilation fan of silo

85 3.3 0.75 0.75 0.661 8.162 0.6052 13.486 4C XLPE 10.0 AL 50 1 80 3.08 3.962 0.078 0.317 0.006 3.419 0.824 0.3 0.954 10.283 2.478
AREA utility building
LT MCC AT SWGR Aux. Supply to Conveying Air
86 5 0.95 0.865 0.502 8.465 0.6052 13.987 4C XLPE 16.0 AL 798 1 225 1.91 2.457 0.080 0.553 0.018 7.143 1.721 0.3 0.954 19.319 4.655
ROOM IN ESP AREA Compressor - A
LT MCC AT SWGR Aux. Supply to Conveying Air
87 5 0.95 0.865 0.502 8.465 0.6052 13.987 4C XLPE 16.0 AL 798 1 220 1.91 2.457 0.080 0.541 0.018 6.984 1.683 0.3 0.954 18.890 4.552
ROOM IN ESP AREA Compressor - B
LT MCC AT SWGR Aux. Supply to Conveying Air
88 5 0.95 0.865 0.502 8.465 0.6052 13.987 4C XLPE 16.0 AL 798 1 215 1.91 2.457 0.080 0.528 0.017 6.826 1.645 0.3 0.954 18.460 4.448
ROOM IN ESP AREA Compressor - C
LT MCC AT SWGR Aux. Supply to Conveying Air
89 5 0.95 0.865 0.502 8.465 0.6052 13.987 4C XLPE 16.0 AL 798 1 210 1.91 2.457 0.080 0.516 0.017 6.667 1.606 0.3 0.954 18.031 4.345
ROOM IN ESP AREA Compressor - D
LT MCC AT SWGR Aux. Supply to Conveying Air
90 5 0.95 0.865 0.502 8.465 0.6052 13.987 4C XLPE 16.0 AL 798 1 205 1.91 2.457 0.080 0.504 0.016 6.508 1.568 0.3 0.954 17.602 4.241
ROOM IN ESP AREA Compressor - E
LT MCC AT SWGR Aux. Supply to Conveying Air
91 5 0.95 0.865 0.502 8.465 0.6052 13.987 4C XLPE 16.0 AL 798 1 200 1.91 2.457 0.080 0.491 0.016 6.349 1.530 0.3 0.954 17.172 4.138
ROOM IN ESP AREA Compressor - F
LT MCC AT SWGR
92 Battery Charger Supply -1 20 0.95 0.865 0.502 33.861 0.6052 55.949 4C XLPE 16.0 AL 798 1 60 1.91 2.457 0.080 0.147 0.005 7.619 1.836 0.3 0.954 20.607 4.966
ROOM IN ESP AREA
LT MCC AT SWGR
93 Battery Charger Supply -2 20 0.95 0.865 0.502 33.861 0.6052 55.949 4C XLPE 16.0 AL 798 1 60 1.91 2.457 0.080 0.147 0.005 7.619 1.836 0.3 0.954 20.607 4.966
ROOM IN ESP AREA
LT MCC AT SWGR
94 AC System-1 (Control Room) 30 0.75 0.75 0.661 74.200 0.6052 122.604 3.5C XLPE 70.0 AL 179 1 30 0.868 0.443 0.074 0.013 0.002 1.470 0.354 0.3 0.954 5.654 1.362
ROOM IN ESP AREA

LT MCC AT SWGR AC System-2 (HCSD Power Pack

95 30 0.75 0.75 0.661 74.200 0.6052 122.604 3.5C XLPE 70.0 AL 179 1 150 0.868 0.443 0.074 0.066 0.011 7.351 1.771 0.3 0.954 28.270 6.812
ROOM IN ESP AREA Unit)

LT MCC AT SWGR
96 ACDB 15 0.75 0.75 0.661 37.100 0.6052 61.302 4C XLPE 35.0 AL 117 1 50 0.868 1.117 0.078 0.056 0.004 2.856 0.688 0.3 0.954 9.472 2.282
ROOM IN ESP AREA

LT MCC AT SWGR
97 BYPASS SUPPLY FOR UPS 17.64706 0.885 0.85 0.527 32.637 0.6052 53.928 3C XLPE 16.0 AL 64 1 60 1.91 2.457 0.080 0.147 0.005 7.225 1.741
ROOM IN ESP AREA

LT MCC AT SWGR MLDB-1 SUPPLY # 1 (AT MAIN

98 88.23529 0.97 0.85 0.527 148.887 0.6052 246.012 3C XLPE 120.0 AL 257 1 50 0.253 0.325 0.071 0.016 0.004 4.051 0.976
ROOM IN ESP AREA AHP COMPLEX)

LT MCC AT SWGR MLDB-1 SUPPLY # 2 (AT MAIN

99 88.23529 0.97 0.85 0.527 148.887 0.6052 246.012 3C XLPE 120.0 AL 257 1 50 0.253 0.325 0.071 0.016 0.004 4.051 0.976
ROOM IN ESP AREA AHP COMPLEX)

LT MCC AT SWGR
100 SILO MCC SUPPLY # 1 237.0653 0.97 0.85 0.527 400.020 0.6052 660.971 1C XLPE 630.0 AL 1628 11 550 0.0778 0.100 0.070 0.005 0.004 4.228 1.01874276
ROOM IN ESP AREA

LT MCC AT SWGR
101 SILO MCC SUPPLY # 2 237.0653 0.97 0.85 0.527 400.020 0.6052 660.971 1C XLPE 630.0 AL 1628 11 550 0.0778 0.100 0.070 0.005 0.004 4.228 1.01874276
ROOM IN ESP AREA

LT MCC AT SILO MLDB-2 SUPPLY # 1 (AT SILO

102 29.41176 0.97 0.85 0.527 49.629 0.6052 82.004 3C XLPE 50.0 AL 142 1 100 0.641 0.825 0.075 0.082 0.008 6.365 1.534
AREA AREA)
LT MCC AT SILO MLDB-2 SUPPLY # 1 (AT SILO
103 29.41176 0.97 0.85 0.527 49.629 0.6052 82.004 3C XLPE 50.0 AL 142 1 100 0.641 0.825 0.075 0.082 0.008 6.365 1.534
AREA AREA)

LT MCC AT SILO
104 Electric Hoist in silo area 4.6 0.75 0.75 0.661 11.377 0.6052 18.799 4C XLPE 16.0 AL 64 1 120 1.91 2.457 0.080 0.295 0.010 4.482 1.080 0.3 0.954 13.845 3.336
AREA

LT MCC AT SWGR 63A Welding Recpetacle (1&2) for

105 40 0.85 0.85 0.527 77.024 0.6052 127.270 3.5C XLPE 70.0 AL 179 1 150 0.868 0.443 0.074 0.066 0.011 8.317 2.004
ROOM IN ESP AREA Ash Water Pump House

5 OF 6
 CLIENT : ESSAR POWER GUJARAT LTD. TITLE : CABLE SIZING CALCULATION FOR LT POWER CABLE FOR AHP
CONSULTANT : TCE CONSULTING ENGG. LTD. DOC NO: 2-A357-DC00-3-0007, REV-5
PROJECT : 2X600 MW THERMAL POWER PLANT AT SALAYA

Voltage Voltage Voltage Voltage

Derated Effective Actual
Full Load Drop in Drop in Motor Drop in Drop in
Derating Current Type Rated No. of Length "R" of "R" of Resist.of Actual
FDR Efficency Power Rated Full No. Of Type Of Cable Cable Starting Cable Cable
SL NO Equipment Description Sin f1 Factor of for Of Selected current Parallel of Cable at Cable at "X" Cable at React. of Sin f2
Rating (η) Factor Load Current Cores Conductor during during p.f. during during
Cable selection Cables carrying Runs Cable 20 DEG-C 90 DEG-C 90 DEG- Cable
(Cos f1) Running Running (Cos f2) Starting Starting
of Cable capacity C
(VMN) (VMN) (VMS) (VMS)
kW % Amps Amps mm² Amps No. Mtrs. Ohms/km Ohms/km Ohms/km Ohms Ohms Volts % Volts %
A B C D E F G H I J K L M N O P Q R S T U V W X
√(1-E²) G/H Nx(1+70x
(C/(DxE)) x 7.2xGx1.73
Resistivity MxO/ MxP/1000 1.732xGx(
FROM TO (1000/1.732x (S/415)x100 √(1-U²) 2x(QxU+Rx W/415x100
of 1000xL) xL) ExQ+FxR)
415) V)
conductor)
LT MCC AT SWGR 63A Welding Recpetacle (3&4) for
106 40 0.85 0.85 0.527 77.024 0.6052 127.270 3.5C XLPE 70.0 AL 179 1 185 0.868 0.443 0.074 0.082 0.014 10.258 2.472
ROOM IN ESP AREA Compressor House
LT MCC AT SWGR 63A Welding Recpetacle (5&6) for
107 40 0.85 0.85 0.527 77.024 0.6052 127.270 3.5C XLPE 70.0 AL 179 1 150 0.868 0.443 0.074 0.066 0.011 8.317 2.004
ROOM IN ESP AREA HCSD Pump House

LT MCC AT SWGR 63A Welding Recpetacle (7, 8 & 9)

108 60 0.85 0.85 0.527 115.536 0.6052 190.906 3.5C XLPE 70.0 AL 179 2 175 0.868 0.443 0.074 0.039 0.006 7.278 1.754
ROOM IN ESP AREA for Dewatering Bin
LT MCC AT SWGR 63A Welding Recpetacle (10) for
109 20 0.85 0.85 0.527 38.512 0.6052 63.635 3.5C XLPE 70.0 AL 179 1 165 0.868 0.443 0.074 0.073 0.012 4.574 1.102
ROOM IN ESP AREA intermediate silo area
LT MCC AT SILO 63A Welding Recpetacle (11 & 12)
110 40 0.85 0.85 0.527 77.024 0.6052 127.270 3.5C XLPE 70.0 AL 179 1 50 0.868 0.443 0.074 0.022 0.004 2.772 0.668
AREA for Silo Utility Building
LT MCC AT SILO 63A Welding Recpetacle (13 & 14)
111 40 0.85 0.85 0.527 77.024 0.6052 127.270 3.5C XLPE 70.0 AL 179 1 100 0.868 0.443 0.074 0.044 0.007 5.545 1.336
AREA for Silo #1 & #2

6 OF 6
CLIENT : ESSAR POWER GUJARAT LTD. TITLE : CABLE SIZING CALCULATION FOR LT POWER CABLE FOR AHP
CONSULTANT : TCE CONSULTING ENGG. LTD. DOC NO: 2-A357-DC00-3-0007, REV-5
PROJECT : 2X600 MW THERMAL POWER PLANT AT SALAYA

A) SAMPLE CALCULATION OF LT CABLE FOR 195KW HP WATER PUMP / CONVEYING AIR COMPRESSOR

1. MINIMUM SIZE FOR SHORT CIRCUIT CURRENT WITHSTAND CAPACITY

Minimum Cross - sectional area of cable `A` to withstand short circuit current = I sh . SQRT(t) / k

Where, I sh = Fault current = 50 KA(rms)

Where, t = Fault clearing time = 0.16 sec (As per TCE specification : 5259A-H-570-002,
SEC: D2.03, CL NO# 3.1.2, SHT 2 OF 6)

k is a constant (for Al. conductor for XLPE insulation) = 0.094

Therefore, A = 212.7660 mm2

Cable size selected for aluminium conductor = 300 mm2

2. DERATING FACTOR

Group rating factors considered for three core cables laid on cable trays exposed to air.

Derating factors for cables are listed below.

For 50 deg.C ambient temperature, derating factor (K1) for XLPE Cable = 0.89 (Ref # Table # 14 of RPG CABLES enclosed).

Group derating factor (K2) for 3no trays & 9 no cables in 1 tray = 0.68 (Ref # Table # 20 of RPG CABLES enclosed).

exposed to air touching each other

Overall derating for cable laid in air (K1xK2) = 0.6052

3. LOAD CURRENT CRITERIA

Motor rating= 195 KW

voltage= 415 V

pf= 0.86

efficiency= 0.93

Full load current = KW* 1000/{ 1.732 *V * PF * EFFI} = 339.2011 A

Actual current flowing (full load current/ derating factor) = 560.4777

Current Rating of 3C-300 sq mm (Al) cable (XLPE), 1100 V Grade in air = 455 A (Refer table#3 of RPG CABLE enclosed)

No of runs = 1.2318

No of runs selected = 2

Hence cable size selected based on load current = 2X3C-300 sq. mm

4. VOLTAGE DROP CRITERIA

Voltage = 415 V

Rated load current through the selected conductor (I in A) = 339.2011 A

Maximum Length (L in mtr.) = 225 mtr

Resistance per Km of the selected cable at 20 DEG c (Ohms/km) = 0.1 ohms/km (Refer table#24 of RPG CABLE enclosed)

Resistance per Km of the selected cable (Ohms/km) AT 90 DEG. = 0.129 ohms/km

Reactance per Km of the selected cable (Ohms/km) at 50 hz = 0.0703 ohms/km

Power factor of the line = 0.85

COS α = 0.85
SIN α = 0.5268

The voltage drop for a given cable length under steady state condition is given by the formula :

{SQRT 3 * I * L*( R COS α + X SIN α)}/(V*NO OF RUN*10) = 1.9435 %

Voltage Drop for 2-3C-300 sq.mm. = 1.944 %

Since this voltage drop is less than the permissible limit of 3% ( Refer CL# 3.1.6 OF SECTION: D2.03, SHT 2 OF 6 OF SPEC NO. TCE-5259A-H-570-002)

Hence cable size of 2x 3C X 300sqmm selected on the basis of Full load current is adequate.

SHEET1
CLIENT : ESSAR POWER GUJARAT LTD. TITLE : CABLE SIZING CALCULATION FOR LT POWER CABLE FOR AHP
CONSULTANT : TCE CONSULTING ENGG. LTD. DOC NO: 2-A357-DC00-3-0007, REV-5
PROJECT : 2X600 MW THERMAL POWER PLANT AT SALAYA

B) SAMPLE CALCULATION OF LT CABLE FOR SILO MCC INCOMER (630A ACB INCOMER)

1. DERATING FACTOR

Group rating factors considered for three core cables laid on cable trays exposed to air.

Derating factors for cables are listed below.

For 50 deg.C ambient temperature, derating factor (K1) for XLPE Cable = 0.89 (Ref # Table # 14 of RPG CABLES enclosed).

Group derating factor (K2) for 3no trays & 9 no cables in 1 tray = 0.68 (Ref # Table # 20 of RPG CABLES enclosed).

exposed to air touching each other

Overall derating for cable laid in air (K1xK2) = 0.6052

2. LOAD CURRENT CRITERIA

Maximum demand on MCC = 278.9003 KVA (Refer Annexure - 1)

System voltage= 415 V

Transmission efficiency = 0.97

Full load current = KW* 1000 / (1.732 *V * PF * EFFI) = 400.0196 A

Actual current flowing (full load current/ derating factor) = 660.9709

Current Rating of 1C-630 sq mm (Al) cable (XLPE), 1100 V Grade in air = 814 A (Refer table#3 of RPG CABLE enclosed)

No of runs = 0.812004

No of runs selected = 1

Hence cable size selected based on load current = 1X1C-630 sq. mm / Phase & 1 run for neutral.

3. VOLTAGE DROP CRITERIA

Voltage = 415 V

Rated load current through the selected conductor (I in A) = 400.0196 A

Aprox Length (L in mtr.) = 550 mtr = 0.55 KM

Resistance per Km of the selected cable (Ohms/km) = 0.0469 ohms/km (Refer table#24 of RPG CABLE

Resistance per Km of the selected cable (Ohms/km) AT 90 DEG. = 0.060 ohms/km enclosed)

Reactance per Km of the selected cable (Ohms/km) at 50 hz = 0.0705 ohms/km

Power factor of the line = 0.85

COS α = 0.85

SIN α = 0.526783

The voltage drop for a given cable length under steady state condition is given by the formula :

{SQRT 3 * I * L*( R COS α + X SIN α)*100}/(V*NO OF RUN) = 8.11853 %

Voltage Drop for 3 RUN 1C-630 sq.mm. / phase = 2.706 %

Since this voltage drop is less than the permissible limit of 3% ( Refer CL# 3.1.6 OF SECTION: D2.03, SHT 2 OF 6 OF SPEC NO. TCE-5259A-H-570-002)

Hence cable size of 3x 1C X 630sqmm / Phase & 2X1C-630 for Neutral selected on the basis of Full load current is adequate.

SHEET2
CLIENT: ESSAR POWER GUJARAT LTD. TITLE: CABLE SIZING CALCULATION FOR LT POWER CABLE
CONSULTANT: TCE CONSULTING ENGG. LTD. DOC NO: 2-A357-DC00-3-0002, REV-5
PROJECT: 2X600 MW THERMAL POWER PLANT AT SALAYA

ANNEXURE-1

ELECTRICAL LOAD 415V SILO MCC AT SILO AREA

SL NO DESCRIPTION NO OF NO OF MOTOR TRANSMISSION MOTOR DUTY POWER AT TOTAL POWER POWER TOTAL KVA
RUNNING STANDBY RATING EFFICIENCY EFFICIENCY FACTOR MOTOR INPUT REQUIREMENT FACTOR
EQUIPMENT EQUIPMENT (KW) TERMINAL (KW)
(KW)
1 SILO AREATION BLOWER 2 1 37 0.95 0.92 0.9 38.1006865 76.201373 0.86 88.6062477
HEATER FOR SILO AREATION
2
BLOWER 2 1 27 1 0.91 0.9 26.7032967 53.40659341 0.86 62.10069
3 DRAIN SUMP PUMP (SILO AREA) 1 1 5.5 1 0.86 0.4 2.558139535 2.558139535 0.86 2.97458085
4 DUST CONDITIONER (ROTARY TYPE) 2 0 11 0.95 0.91 0.9 11.45170619 22.90341238 0.87 26.3257614
5 TELESCOPIC CHUTE FOR FA SILO 2 0 2.2 1 0.8 0.9 2.475 4.95 0.82 6.03658537
6 SILO VENT FAN 2 0 7.5 1 0.83 0.9 8.13253012 16.26506024 0.85 19.135365
7 ROTARY FEEDER BELOW FA SILO 2 0 2.2 0.95 0.8 0.9 2.605263158 5.210526316 0.82 6.35430039
8 HOIST IN SILO UTILITY BUILDING 1 0 4.6 0.4 0.85 0.4 5.411764706 5.411764706 0.85 6.36678201
9 WELDING RECEPTACLE 16
10 LIGHTING LOAD 25
11 ACDB 10
12 CONTROL & AUXILIARY 10
TOTAL KVA REQUIRED = 278.900313 KVA
CONSIDERING 10% MARGIN = 306.790344 KVA
 In duct at 30

AC current rating of Cu
degC (A)

cable (in trefoil)

In ground at 30
degC (A)

In air at 40 degC
(A)

In duct at 30
degC (A)
AC current rating of AL
cable (in trefoil)

In ground at 30
degC (A)

In air at 40 degC
(A)

Aprox. weight -
Cu conductor
(Kg.)
Aprox. weight -
AL conductor
(Kg.)
Aprox. overall
diameter (mm)
Armoured

Nominal Al. arm.

size- strip (mm)

Nominal Al. arm.

size- wire (mm))

Nominal
thickness of
insulation (mm)
Aprox. weight -
Cu conductor
(Kg.)
Aprox. weight -
Unarmoured

AL conductor
(Kg.)
Aprox. overall
diameter (mm)

Nominal
thickness of
insulation (mm)
Area of
conductor (mm2)

Number of cores
 In duct at 30
degC (A)

AC current rating of Cu
cable (in trefoil)
In ground at 30
degC (A)

In air at 40 degC
(A)

In duct at 30
degC (A)
AC current rating of AL
cable (in trefoil)

In ground at 30
degC (A)

In air at 40 degC
(A)

Aprox. weight -
Cu conductor
(Kg.)
Aprox. weight -
AL conductor
(Kg.)
Aprox. overall
diameter (mm)
Armoured

Nominal Al. arm.

size- strip (mm)

Nominal Al. arm.

size- wire (mm))

Nominal
thickness of
insulation (mm)
Aprox. weight -
Cu conductor
(Kg.)
Aprox. weight -
AL conductor
Unarmoured

(Kg.)
Aprox. overall
diameter (mm)

Nominal
thickness of
insulation (mm)
Area of
conductor (mm2)

Number of cores
 In duct at 30

AC current rating of Cu
degC (A)

cable (in trefoil)

In ground at 30
degC (A)

In air at 40 degC
(A)

In duct at 30
degC (A)
AC current rating of AL
cable (in trefoil)

In ground at 30
degC (A)

In air at 40 degC
(A)

Aprox. weight -
Cu conductor
(Kg.)
Aprox. weight -
AL conductor
(Kg.)
Aprox. overall
diameter (mm)
Armoured

Nominal Al. arm.

size- strip (mm)

Nominal Al. arm.

size- wire (mm))

Nominal
thickness of
insulation (mm)
Aprox. weight -
Cu conductor
(Kg.)
Aprox. weight -
Unarmoured

AL conductor
(Kg.)
Aprox. overall
diameter (mm)

Nominal
thickness of
insulation (mm)
Area of
conductor (mm2)

Number of cores
 In duct at 30

AC current rating of Cu
degC (A)

cable (in trefoil)

In ground at 30
degC (A)

In air at 40 degC
(A)

In duct at 30
degC (A)
AC current rating of AL
cable (in trefoil)

In ground at 30
degC (A)

In air at 40 degC
(A)

Aprox. weight -
Cu conductor
(Kg.)
Aprox. weight -
AL conductor
(Kg.)
Aprox. overall
diameter (mm)
Armoured

Nominal Al. arm.

size- strip (mm)

Nominal Al. arm.

size- wire (mm))

Nominal
thickness of
insulation (mm)
Aprox. weight -
Cu conductor
(Kg.)
Aprox. weight -
Unarmoured

AL conductor
(Kg.)
Aprox. overall
diameter (mm)

Nominal
thickness of
insulation (mm)
Area of
conductor (mm2)

Number of cores
Electrostatic
capacitance
(uF / Km)

Voltage Drop
- Cu (V/A/
Km)

Voltage Drop
- AL (V/A/Km)

Impedance -
Cu (Ohm/Km)

Impedance -
AL (Ohm/
Km)

Reactance -
(Ohm/Km)

AC
resistance -
Cu (Ohm/
Km)
AC
resistance -
AL (Ohm/
Km)

Max. DC
resistance -
Cu (Ohm/
Km)

Max. DC
resistance -
AL (Ohm/
Km)

NMinimum
no of wires -
Class-2 (Cu)

Minimum no
of wires -
Class-2 (AL)

Nominal size
of conductor
(mm2)
Electrostatic
capacitance
(uF / Km)

Voltage Drop
- Cu (V/A/
Km)

Voltage Drop
- AL (V/A/Km)

Impedance -
Cu (Ohm/Km)

Impedance -
AL (Ohm/
Km)

Reactance -
(Ohm/Km)

AC
resistance -
Cu (Ohm/
Km)
AC
resistance -
AL (Ohm/
Km)

Max. DC
resistance -
Cu (Ohm/
Km)

Max. DC
resistance -
AL (Ohm/
Km)

NMinimum
no of wires -
Class-2 (Cu)

Minimum no
of wires -
Class-2 (AL)

Nominal size
of conductor
(mm2)