PRINCIPLES OF CABLE SIZING AND SELECTION By Anthony G.

Quiogue Fluor Philippines

Presented at the 37th Annual National Convention of the Institute of Integrated Electrical Engineers of the Philippines, Inc

November 14 - 17, 2012

ABSTRACT The use of cable ampacity tables is the most common method of selecting and sizing cables for a certain use or application. However, there is the danger of selecting the wrong cable if the condition for which the table is developed is misunderstood. Cable sizing, and consequent selection for a definite application is governed by the following factors: load duty, short circuit or transient duty, the cables inherent characteristics, as determined by its construction and materials, and external factors such as ambient conditions, laying conditions, and proximity to other heat sources including other cables. This presentation aims to explain how these factors contribute and interact, thereby affecting the cables ampacity and circuit performance. With such understanding, and with correct application of such principles, the correct methodology of sizing and selecting cables for a given duty is assured.

Introduction There are several aspects of selecting cables for a given application. Among the most important are the following: type of installation or laying conditions, voltage rating, ambient conditions, and the most important aspect, ampacity. Cables can be installed aboveground (in conduit or in enclosed raceway), strung out between poles or in messenger wire, or laid in a cable tray. Cables can be installed underground (below grade) as direct buried cables, in buried conduits, or they can be laid in a trench by various means (supported on racks, installed in conduit, or in a tray), or they can be installed in underground duct banks. Moreover, various methods of installation subject the cables to various ambient conditions such as changing ambient temperature and the presence or absence of moisture (wet, damp or dry locations). Cables are also manufactured to meet specific voltage requirements of the circuit they comprise and selection is somewhat straightforward in this aspect. The more complicated issue in cable selection is choosing on the basis of ampacity. The first step in this process is to establish the ampere requirement of the circuit. The primary consideration is load duty. The Philippine Electrical Code (PEC) has specific rules for calculating ampacity requirements for branch circuits and feeders. As electrical engineers we should be well versed in this competency. Having calculated the required ampacity, the next step is to select the cable type, with consideration of the aforesaid aspects such as type of installation, voltage rating, and ambient conditions. After selecting the type the next step is to carefully determine the cable ampacity corrected for variant conditions of installation intended for the cables use. Let us discuss more of these factors in detail.

Cable Selection Cable selection involves carefully considering the following factors: Voltage Cables are rated for a certain voltage of application. Common building wires are rated for 600 Volts. In the Code, generally, rules of application are divided into for cables 0 to 2000 Volts and for cables over 2000 Volts. Choose the cables appropriate for the intended use. Insulation type The insulation types are marked on the cables. These markings identify the insulation material. Choosing the insulation type necessitates knowing the following: The maximum temperature the cable will be allowed to reach in use. This is greatly influenced by: Ampacity requirements of the load. This sets the minimum requirement in sizing a conductor for use. Terminal provisions of connected equipment o Those rated 100 A or less or marked for 38 sq mm or less shall have conductors rated 60C connected to them; conductors rated 75C can be used if the ampacity is determined at 60C rating. Those rated more than 100 A or marked for more than 38 sq mm shall be allowed to have 75C rated conductors connected. Higher temperature rating conductors shall be allowed if their ampacities are determined at 75C. Higher conductor ratings may be used if the equipment is listed and identified for use with such higher temperature

The moisture factor: whether the condition of installation is dry, wet, or damp Cable Construction This factor will be determined primarily by the design installation conditions. This factor consists of the following: Whether solid or stranded, for small conductors Whether a jacket is applied over the insulation, over a set of conductors, or over armoring Whether the cable is single conductor or multiconductor For multiconductors, the number of core conductors For multiconductors, whether the ground wire and/or the neutral is integrated with the cable Additional covering or whether shielding and/or armoring or metal sheathing is desired: shielding is basically for electromagnetic isolation, armoring is for mechanical protection while metal sheathing provides water-tight protection. For example, lead sheathed cables are common in the petroleum industry. Cable construction also determines resistance to damaging environmental conditions. Whether the insulation or additional covering is needed to afford chemical resistance, radiation resistance, flame resistance, flame retardance, ozone, oil or fungus resistance, etc Ampacity The most important factor to consider is cable ampacity. Basically, it should match the requirement of the circuit, that is, the demand of the load. After the ampacity is determined, the following conditions should then be checked and the size of the conductor adjusted as necessary: Voltage drop. The Code recommends a maximum combined voltage drop of 5% for branch circuit and feeders. A related issue is the necessary check on the terminal voltages of control and protective device, to ensure that they will operate as required. The basic rule in the Code is that conductors shall be protected against overcurrent at their derated ampacities. Protective device rating. The PEC states that o o The next higher size of protective device rating shall be permitted for ampacities 800 amperes or less. The next higher size of protective device shall be used for ampacities higher than 800 amperes.

Ampacity --- Definition Ampacity is defined in the PEC (Article 1.1) as the current, in amperes, that a conductor can carry continuously under conditions of use without exceeding its temperature rating. This definition gives us the following points to consider: 1. Ampacity is a continuous current rating of the conductor; 2. The conditions of use MUST be specified, 3. The conductors temperature rating MUST not be exceeded The mechanics for the rise in temperature in a conductor must also be understood to fully appreciate the limitations and imposed by the conditions of use on cable ampacity.

Consider a conductor with resistance R carrying an amount of impressed current I. The current will generate heat within the conductor at the rate P according to the following power formula P = I2R. To a lesser degree heat is also generated by induced currents in the other metallic components of the cable, if present. Among these are metallic sheaths and armors. Losses in the dielectric materials surrounding the conductor also contribute to heat generation (insulation, shields, screen, jacket and serving/bedding). Other heat sources (e.g. other current-carrying conductors nearby) contribute heat to the conductor as well as to the environment surrounding that conductor. All the generated heat tends to raise the temperature of the conductor material. With a sufficient combination of current and time, (I2t), the conductor, and its insulation will attain a higher temperature than the ambient (air or soil). The difference in temperature gives rise to the transfer of heat from the cable to the environment. This transfer occurs by way of conduction, convection and radiation Conduction is the transfer of heat from molecule to molecule and generally occurs predominantly if the material surrounding or touching the cable is solid, such as earth Convection occurs if the material surrounding the cable is a moving fluid such as air, oil or water. Convection is the transfer of molecules (and therefore with it, heat) either by bulk or significant diffusion Thermal radiation is another mode of heat transfer although a less significant one under normal temperature ratings

Generally all modes of heat transfer operate. Conductors in a raceway in earth will have convection operating in the air within the duct and conduction from the duct to the earth The rate at which heat is transferred to the environment is affected by temperature difference as well as the thermal barriers between the conductor and the environment. Thermal barriers include the insulation, jacketing, air inside raceway, the raceway itself, soil, concrete, building materials, and any thermal insulation applied such as fireproofing. If an equilibrium is attained between the rate of heat transfer and the rate of heat generation, a steady state temperature is achieved by the conductor which is also the temperature at the boundary with the insulation. The conductor can normally withstand the temperature developed within it. However, the insulation enclosing the conductor has temperature limits as determined by its thickness and composition. This limit is termed the conductors maximum operating temperature The object therefore of defining the ampacity of a specific conductor is to set the value of current at which the maximum operating temperature will not be exceeded. Factors Affecting Cable Ampacity - Inherent Cable Characteristics The PEC recognizes inherent cable characteristics, determined by design and manufacture, which set the fundamental parameters for a cables ampacity rating. Among these are: Conductor characteristics a Conductor material b Conductor size

Insulation characteristics a Type of material b Thickness Construction a Single conductor or multi-conductor b Presence of jacketing, coverings, sheathing and armoring

These characteristics in turn, determine the following Application provisions (voltage, location and type of installation) Temperature rating (maximum operating temperature) Conductor Material The material of the conductor affects the ampacity because the resistivity, and hence the resistance, for a given size is determined by the type of material The formula for resistance is as follows: R = L/A Where R is the conductors d.c. resistance, is the conductor material resistivity constant, L is the length and A is the cross-sectional area. The most common conductor materials are copper, with a resistivity of 1.68 x10-8 ohmm at 20oC, and aluminum with a resistivity of 2.82 x10-8 ohmm at 20oC Conductor Size From the same formula it is noted that resistance is inversely proportional to the cross sectional area. Therefore, the smaller the wire diameter, the greater the resistance for any given length, all other factors being equal. Example: A copper conductor of size 10 mm2 has a resistance of 1.68 Ohm/km while a one of size 16 mm2 has a resistance of 1.05 Ohm/km. Wire sizes in the PEC are designated in terms of square millimeters (mm2). Insulation Types Electrical conductors are normally coated or wrapped in insulating materials to isolate conductors from one another as well as provide some sort of mechanical protection. There are various insulation material types used for conductor insulation. Among the common ones are: Natural polymers such as paper, cotton and natural rubber Synthetic polymers such as thermoplastic materials (e.g. PVC and fluorinated plastics) and thermosetting materials (e.g. synthetic rubber, cross-linked polyethylene, and silicone rubber) Mineral insulation

The different insulation types offer different characteristics which, together with insulation thickness, determine the application conditions for which these types will be allowed. Among these characteristics are: Dielectric strength Resistivity Flame and Heat resistance Resistance to abrasion, cracking, crushing and impact Insulation Thickness Cables are wrapped in varying thicknesses of insulation. The PEC specifies required insulation thicknesses for listed insulation types. The thicker the insulation, the better it can withstand an applied voltage before breaking down, so generally, the higher the conductors voltage rating the thicker the insulation. Aside from providing electrical isolation, insulation should also provide some mechanical protection The PEC Tables 3.10.1.13, 3.10.61, 3.10.62, 3.10.63, 3.10.64 list approved insulation type, materials, maximum operating temperatures and thickness for various cable insulations. In fact the code defines insulated conductor as one encased within material of composition and thickness that is recognized by the code as electrical insulation. This recognition is documented in these tables. Conductors not meeting the required insulation type and minimum thickness of encasing material are classified as covered conductors only. Insulation Temperature Rating Insulated conductors are characterized by a specific maximum operating temperature rating based on the type and thickness of insulation employed on the conductor. As mentioned above the object of defining the ampacity of a specific conductor is to set the value of current at which the maximum operating temperature will not be exceeded. Higher-temperature rated insulation allows a conductor of the same size to be used at a higher ampacity than a conductor with lower-temperature rated insulation. Example: A copper conductor of size 8 mm2 has an ampacity of 40 amperes if the insulation is rated 60oC (Types TW, UF) but has an ampacity of 50 amperes if the insulation is rated 75oC (Types RHW, THHW, THW, THWN, XHHW, ZW) as per PEC Table 3.10.1.16 Factors Affecting Cable Ampacity External Conditions Ambient Temperature Ambient temperature is the temperature of the material surrounding the conductor, and can either be the air for aboveground installations, or the earth for underground installations The ambient temperature determines the temperature gradient about the conductor. It therefore affects the rate of transfer of heat from the conductor to the environment. Ampacity ratings are defined based on a given ambient temperature. If there is a significant difference between the actual (operating) ambient and the ambient at which the cable is rated, ampacity is correspondingly adjusted

Installation Conditions Installation methods affect the way generated heat is transferred to the environment and can be one of the following Free air A cable installation that is not enclosed in a raceway or routed underground and allows the surrounding air to flow freely. With this type of installation, cable conductors can more easily cool to the ambient air temperature. Installation of this type can be one of the following: Open Wiring on Insulators - An exposed wiring method using single insulated conductors supported on insulators run in or on buildings. Messenger Supported Wiring - An exposed wiring support system using messenger wire to support insulated conductor. Cable Tray Ladders and ventilated troughs allow free flow of air around the conductors (However, covered solid bottom cable trays restrict the flow of air by practically enclosing the conductors) Cables directly buried in earth tend to cool to the ambient earth temperature. Ambient earth temperature varies with location, season and depth. Typical values in temperate countries are 15oC in winter and 25oC in summer. In the PEC tables, the reference ambient earth temperature of direct buried cables is 20oC. Depth of installation also affects cable ampacity of direct buried cables. A 6% derating in ampacity (that is multiply the ampacity by 94%) for every 300 mm increase in depth of laying from the value specified in the Code. Raceway - metal conduit or nonmetallic conduit, tubing, wireways, trunking and ducts, Cable installations using raceways could either be aboveground or underground. Ambient air temperature is the reference for aboveground installations while ambient earth temperature is the reference for installations underground. Likewise for underground ducts, depth of installation also affects cable ampacity of direct buried cables. A 6% derating in ampacity (that is multiply the ampacity by 94%) for every 300 mm increase in depth of laying from the value specified in the Code When several wires or cables are grouped together in a run, each one gives off heat and affects ampacity by Transferring generated heat directly to other cables, and/or Raising the immediate ambient air or earth temperature, thereby diminishing the temperature gradient or difference,

Directly buried in earth

Enclosed type of installations restrict the flow of air

Grouping with other cables.

The net effect is to decrease the individual cables rate of heat transfer. This necessitates a reduction of cable ampacity so as not to let the temperature of the conductor rise to a level injurious to the insulation.

Each of the PEC ampacity tables defines under what grouping conditions the listed ampacity values hold true. When actual grouping condition differ from what is defined in the ampacity tables, adjustment factors for derating or reduction of ampacity rating is required by the code

Ampacity Determination The PEC allows two methods of determining the ampacity of conductors: 1. By tables 2. By calculation under engineering supervision by the use of the Neher-McGrath There are twenty six (26) ampacity tables in the PEC, six for cables 0 2000 V, and twenty for cables over 2000 V

Using the PEC Ampacity Tables: The use of the PEC ampacity tables require understanding the conditions under which the tables were developed. Deviations from the defined conditions require the application of adjustment factors, specifically for ambient temperature and installation condition including grouping. PEC Ampacity Tables There are six ampacity tables for cables rated 0 2000V in the PEC. Below is the tabulated data for ampacity Tables 3.10.1.16 to 3.10.1.21 Table No. Conductor Construction / Installation Ambient Conductor Type Temperature Grouping Condition Temperature Installed in Insulated raceway, conductors, not Copper/Aluminum or cable, or earth 30 deg C 60-75-90 deg C more than three copper-clad aluminum (directly current-carrying buried) conductors 60-75-90 deg C Single-insulated Copper/Aluminum or Free air conductors copper-clad aluminum Copper/Nickel or nickel-coated Raceway or copper/Aluminum or cable copper-clad aluminum 30 deg C

3.10.1.16

3.10.1.17

3.10.1.18

Insulated conductors, not 150-250 deg C more than three current-carrying conductors 150-200-250 deg C

40 deg C

3.10.1.19

3.10.1.20

75-90 deg C

Copper/Nickel or Single-insulated nickel-coated Free air 40 deg C conductors copper/Aluminum or copper-clad aluminum Not more than Copper/Aluminum or Supported on three single40 deg C copper-clad aluminum a messenger insulated conductors Bare or covered Copper/AAC conductors Aluminum Free air, 40 deg C 610mm/sec wind velocity

3.10.1.21

80 deg C

There are twenty ampacity tables for cables rated 2001 35,000V in the PEC. Below is the tabulated data for ampacity tables 3.10.1.67 to 3.10.1.86 Table No. 3.10.1.67 3.10.1.68 3.10.1.69 3.10.1.70 3.10.1.71 3.10.1.72 3.10.1.73 3.10.1.74 3.10.1.75 3.10.1.76 3.10.1.77 3.10.1.78 3.10.1.79 3.10.1.80 3.10.1.81 3.10.1.82 3.10.1.83 3.10.1.84 3.10.1.85 3.10.1.86 90-105 deg C Conductor Temperature 90-105 deg C 90-105 deg C 90-105 deg C 90-105 deg C 90-105 deg C Conductor Type Copper Insulated single conductor cables Aluminum Copper Insulated single conductor cables Aluminum Copper Insulated threeconductor cables Aluminum Insulated triplexed or Copper three singleAluminum conductor cables Copper Insulated threeconductor cables Aluminum Construction Copper Aluminum Copper Aluminum Copper Aluminum Copper Aluminum Copper Aluminum Installation Condition Triplexed in air Isolated in air Isolated in air Isolated conduit in air Isolated conduit in air In underground electrical ducts (3 conductors per duct) RHO of 90, 100% load factor In underground electrical ducts (one cable per electrical duct) RHO of 90, 100% load factor Directly buried in earth, RHO of 90, 100% load factor Directly buried in earth, RHO of 90, 100% load factor Directly buried in earth, RHO of 90, 100% load factor Ambient Temperature 40 deg C 40 deg C 40 deg C 40 deg C 40 deg C

Three single90-105 deg C insulated conductors Three insulated conductors cabled 90-105 deg C within an overall covering (threeconductor cable) Single insulated copper conductors

20 deg C

20 deg C

20 deg C

Three insulated conductors cabled 90-105 deg C within an overall covering (threeconductor cable) Three triplexed 90-105 deg C single insulated copper conductors

20 deg C

20 deg C

Note: For underground duct and directly buried cables, see Figure 3.10.1.60 of the PEC for cable installation dimensions.

There are eight other ampacity tables included in Appendix B of the 2009 Philippine Electrical Code. These tables, summarized below, are not part of the Code per se but they provide ampacity information for conditions not described in the tables within the Code.

Cables rated 0 to 2000V, Copper/Aluminum or copper-clad aluminum Table No. Conductor Temperature Construction / Grouping Installation Condition Ambient Temperature In air (UON)

B-310-1

B-310-3

2 to 3 Insulated conductors, with 60-75-90 deg C overall covering (multiconductor cable) Multiconductor 60-75-85-90 deg C with at most 3 (cable type TC, MC, Insulated MI, UF and USE conductors 75 deg C Single Insulated conductors

Installed in raceway in free 30 deg C air

In Free air In Non-magnetic Underground duct (one conductor per duct)

40 deg C

B-310-5

20 deg C (earth) 20 deg C (earth)

B-310-6

75 deg C

Three-Conductor In Underground duct (one Cable cable per duct) Three Single Insulated conductors 2 to 3 Insulated conductors, with overall covering (multiconductor cable) 3 triplexed single insulated conductor Three Single Insulated Conductors

B-310-7

75 deg C

In Underground duct (three 20 deg C conductors per duct) (earth)

B-310-8

60-75 deg C

Directly Buried, 100% Load 20 deg C factor, RHO of 90 (earth)

B-310-9

60-75 deg C

Directly Buried, 100% Load 20 deg C factor, RHO of 90 (earth) Directly Buried, 100% Load 20 deg C factor, RHO of 90 (earth)

B-310-10

60-75 deg C

Note: For underground duct and directly buried cables, see Figure B-310-2 of the PEC for cable installation dimensions.

The Tables of Ampacities in the PEC are characterized by the very specific parameters described above. Some of these (voltage, maximum operating temperature, conductor material, construction) are either inherent characteristics of the cable or are designated by the manufacturer based on standard tests. They are the first filters to be used when selecting cables. Each of these parameters should be understood when applying the ampacity tables. Any deviation from these parameters can mean one of the following: 1. The table is not applicable 2. The table is applicable but adjustment factors have to be used There are two parameters for which deviations from the listed condition in the NEC ampacity tables can be compensated (or will be modified) by use of adjustment factors: 1. Ambient temperature (air or earth) 2. Grouping and/or installation conditions Adjustment Factors for Ambient Temperature. For cables rated 0 to 2000 V, the adjustment factors for deviations from listed ambient are tabulated at the bottom of each ampacity table. Below is an example for the factors for table 3.10.1.16

For cables rated over 2000 V, the adjustment of ampacity for deviations from listed ambient are determined from the following formula

I 2 I1
Where
I1 I2 TC TA1 TA2

TC TA2 TD TC TA1 TD

= Ampacity from tables at ambient TA1 = Ampacity at desired ambient TA2 = Conductor temperature in degrees Celsius (oC) = Surrounding ambient from tables in degrees Celsius (oC) = Desired ambient in degrees Celsius (oC)

TD = Dielectric loss temperature rise

Note that the same formula is valid for cables rated for 0 to 2000 volts by ignoring the terms TD, the dielectric loss temperature rise.

Grouping with other cables Each of the PEC ampacity tables define under what grouping conditions the listed ampacity values hold true. By way of example, the following table header from the PEC table 3.10.1.16 is shown:

Thus the table is expressed as valid for Not More Than Three Current-Carrying Conductors in Raceway, Cable or Earth (Directly Buried) When actual grouping condition differ from what is defined in the ampacity tables, adjustment factors for derating or reduction of ampacity rating is required by the code Table 3.10.15(b)(2)a lists the adjustment factors for more than three current- carrying conductors in a raceway or cable. Neutral conductors carrying only the unbalanced current from the same circuit as well as grounding and bonding conductors are not counted as current-carrying conductors specified in the table.

There are exceptions to the application of the factors listed in Table 3.10.15(b)(2)a. The more significant exceptions are Derating factors apply only to power and lighting cables. Derating factors do not apply to conductors in nipples not exceeding 610 mm (24 inches) Derating factors do not apply to not more than four conductors entering or leaving an outdoor trench protected by rigid metal conduit, intermediate metal conduit or rigid non-metallic conduit not exceeding 3.05 m (10 ft) Cable installed in cable trays. This is discussed in detail in the topic Ampacity of Cables in Cable Tray Cable installed in metal wireways (and similar raceways). This is discussed in the topic Ampacity of Cables in Metal Wireways and Similar Raceways

Ampacity of Cables in Cable Tray The PEC has definite rules for cables installed in cable trays. Even in the ways of installing cables in a cable tray, is governed by specific rules. These rules generally specify the type, number and sizes of cables that can be laid in a certain tray type (Cable ladder, ventilated through, ventilated channel, or solid bottom) and size, and whether the cables can be laid in a single layer, or in multiple layers. Consequently these rules also determine the size of trays that should be used for a given collection of cables. The topics of cable installation in cable trays and the sizing of cable trays are quite broad and will not be discussed here. Suffice it to say, that compliance with the rules is a precondition of the PEC in allowing the use of available ampacity tables in the code for cables in cable trays. For multiconductor cables rated 2000 volts or less, the following tables are used Table No. Conductor Construction / Temperature Grouping Insulated conductors, not 3.10.1.16 60-75-90 deg C more than three current-carrying conductors Insulated conductors, not 3.10.1.18 150-250 deg C more than three current-carrying conductors 60-75-85-90 Multiconductor deg C (cable with at most 3 B-310-3 type TC, MC, Insulated MI, UF and conductors USE Conductor Type Installation Condition Ambient Temperature

Installed in Copper/Aluminum or raceway, cable, or 30 deg C copper-clad aluminum earth (directly buried) Copper/Nickel or nickel-coated Raceway or cable 40 deg C copper/Aluminum or copper-clad aluminum Copper/Aluminum or In Free air copper-clad aluminum

40 deg C

The conditions for using the ampacities in these tables are as follows: The multiconductor cables are installed in accordance with the requirements of the code as detailed in 3.92.1.9. The derating factors for more than three current-carrying conductors in a raceway or cable (table 3.10.1.15(b)(2)a are applicable only to each cable and not to the total number of conductors in a tray. Ampacities for multiconductor cables shall be as shown in tables 3.10.1.16 or 3.10.1.18, as applicable. When a cable tray is covered for more than 1.8 meters, a derating factor of 0.95 is applied to the ampacities in the tables 3.10.1.16 or 3.10.1.18. When multiconductor cables are installed in a single layer, with a minimum spacing of 1 cable diameter, the ampacities in table B-310-3 can be used.

For single conductor cables rated 2000 volts or less, the ampacities in following tables are used: Table No. 3.10.1.17 Conductor Construction / Conductor Type Temperature Grouping 60-75-90 deg C 150-200-250 deg C Installation Condition Ambient Temperature 30 deg C

Single-insulated Copper/Aluminum or Free air conductors copper-clad aluminum

3.10.1.19

3.10.1.20

75-90 deg C

Copper/Nickel or Single-insulated nickel-coated Free air 40 deg C conductors copper/Aluminum or copper-clad aluminum Not more than Copper/Aluminum or Supported on three single40 deg C copper-clad aluminum a messenger insulated conductors

The conditions for using the ampacities in these tables are as follows: The single conductors are installed in accordance with the requirements of the code as detailed in 3.92.1.10, and are 50 sq mm or larger. The derating factors for more than three single current-carrying conductors in a raceway or cable shall not apply to the ampacity of conductors in a cable tray. Ampacities for conductors 325 sq mm and larger shall not exceed 75% of the values listed in the tables 3.10.1.17 and 3.10.1.19. If the tray is covered for 1.8 meters or more, ampacities shall not exceed 70% of the listed values in these tables. Ampacities for conductors 50 sq mm through 250 sq mm shall not exceed 65% of the values listed in the tables 3.10.1.17 and 3.10.1.19. If the tray is covered for 1.8 meters or more, ampacities shall not exceed 60% of the listed values in these tables. Ampacities for single conductors, when installed in a single layer in an uncovered cable tray, with a spacing of not less than one cable diameter between conductors, shall be as listed in tables 3.10.1.17 and 3.10.1.19. When single conductors are installed in triangular (trefoil) or square configuration, in an uncovered cable tray, with a maintained spacing of 2.15 times the conductor diameter of the largest conductor in the configuration, ampacities listed in table 3.10.1.20 can be used. For multiconductor cables rated 2001 or over, the following tables can be used Table No. 3.10.1.71 3.10.1.72 3.10.1.75 3.10.1.76 90-105 deg C 90-105 deg C Conductor Construction Temperature Insulated threeconductor cables Insulated threeconductor cables Conductor Type Copper Aluminum Copper Aluminum Isolated conduit in air 40 deg C Isolated in air 40 deg C Installation Condition Ambient Temperature

The conditions for using the ampacities in these tables are as follows:

The multiconductor cables are installed in accordance with the requirements of the code as detailed in 3.92.1.12. Ampacities for multiconductor cables shall be as shown in tables 3.10.1.75 or 3.10.1.76, as applicable. When a cable tray is covered for more than 1.8 meters, a derating factor of 0.95 is applied to the ampacities in these tables. When multiconductor cables are installed in a single layer in an uncovered cable tray, with a minimum spacing of 1 cable diameter, the ampacities shall not exceed the values in tables 3.10.1.71 or 3.10.1.72.

For single conductor cables rated 2001 or over, volts or less, the ampacities in following tables are used: Table No. 3.10.1.67 90-105 deg C 3.10.1.68 3.10.1.69 3.10.1.70 90-105 deg C Conductor Construction Temperature Conductor Type Installation Condition Triplexed in air Ambient Temperature 40 deg C

Copper Insulated single conductor cables Aluminum Insulated single Copper conductor cables Aluminum

Isolated in air

40 deg C

The conditions for using the ampacities in these tables are as follows: The single conductors are 50 sq mm or larger and are installed in accordance with the requirements of the code as detailed in 3.92.1.12. The derating factors for more than three single current-carrying conductors in a raceway or cable shall not apply to the ampacity of conductors in a cable tray. Ampacities for conductors in uncovered cable trays shall not exceed 75% of the values listed in the tables 3.10.1.69 or 3.10.1.70 as applicable. If the tray is covered for 1.8 meters or more, ampacities shall not exceed 70% of the listed values in these tables. When single conductors are installed in triangular (trefoil) or square configuration, in an uncovered cable tray, with a maintained spacing of 2.15 times the conductor diameter of the largest conductor in the configuration, with the adjacent conductor, ampacities listed in table 3.10.1.67 or 3.10.1.68 can be used.

Ampacity of Cables in Metal Wireways and Similar Raceways Some raceways allowed by the Code are structurally extended boxes with covers, which have larger cross sectional areas than typical conduit-type or tubing-type raceways and therefore afford larger space for conductors. The following raceway types fall under this category: Sheet metal auxiliary gutters Metal wireways Strut type Channel raceways Surface metal raceways

Generally, the rules governing ampacities of cables installed in these types of raceways are: The sum of the cross sectional area of all contained conductors shall not exceed 20% of the interior cross-sectional area of the raceway at any point. The derating factors for more than three single current-carrying conductors in a raceway or cable shall NOT be applied if the number of conductors is 30 or less. Conductors for signaling, control or communication are not counted as current-carrying conductors. For strut-type channel, and surface metal raceways, an additional condition for the derating NOT apply is that the channel or surface raceway have cross sectional area of at least 2500 sq mm. Non-metallic auxiliary gutter, non-metallic wireway are not exempted from the application of the derating factor, regardless of the fill or number of conductors. The Neher-McGrath Equation The Neher-McGrath equation is another method that can be used in calculating for cable ampacity under engineering supervision as the PEC requires. The Neher-McGrath formula is a heat transfer formula, comprising a series of heat transfer calculations that takes into account all heat sources and the thermal resistances between the heat sources and free air. The most common use of this formula is to calculate for the ampacity of conductors in underground electrical ducts (raceways), although the formula is also applicable to all conductor installations.

To understand how the formula relates to ampacity we need to examine how heat is transferred in respect to a current carrying conductor. When current flows through a conductor heat is generated. The heat passes through several thermal barriers by convection, conduction, and radiation and dissipates into the air. Possible thermal barriers are the conductor insulation, the air inside a duct, the duct wall, the concrete encasement, the soil surrounding the duct, and any additional thermal insulation applied. The rate of heat transfer is dependent on several variables and can be described by a thermal equation that closely resembles ohms law (E=I x R), substituting heat for current and thermal resistance for electrical resistance. In a heat transfer equation the rate of heat transfer is directly dependent on the difference in temperature between the conductor called TC and the ambient temperature called TA. In a heat transfer equation TC-TA = (I x I x R) x RCA, where I is current in amperes, R is electrical resistance in ohms, and RCA is thermal resistance in degrees Centigrade-cm/watt usually called thermal-ohm-feet. TC is the maximum permissible operating temperature in degrees Centigrade of the conductor. TA is the ambient temperature of the air or soil for underground installations. Solving for I: Equation 1
I TC TA RxRCA

Equation No. 1 is also called the Fourier heat transfer equation.

The equation in section 3.10.1.15(c) and section 3.10.1.60(d) of the PEC, called the NeherMcGrath equation, is a more complex version of the Fourier heat transfer equation. This is shown here as equation 2: Equation 2 Where
I = Ampacity, (kiloamperes) TC = Conductor temperature, (Deg C) TA = Ambient temperature in degrees C TD = Conductor temperature rise due to dielectric loss, (Deg C) RDC = Conductor dc resistance, (micro-ohms/foot) YC = Loss increment due to conductor skin and proximity effects RCA = Thermal resistance between conductor and ambient, (thermal ohm feet)

TC (TA+TD) RDC(1+YC)RCA

This equation was developed by J.H. Neher and M.H. McGrath and presented in a paper entitled The Calculation of the Temperature Rise and Load Capability of Cable Systems to AIEE (American Institute of Electrical Engineers) the precursor to the organization IEEE. In this equation, TD, is a term added to the ambient temperature, TA, to account for the heat generated in the insulation and other covering of dielectric material. It represents the temperature rise arising from dielectric loss. It is insignificant for voltages below 2000. Another term in the NM equation, (1+YC), is a multiplier to convert direct current resistance (RDC) to alternating current resistance. For small wire sizes this term becomes insignificant.

Although the equation looks deceptively simple, the application to actual cable configurations can be daunting. Appendix B of the PEC contains ampacity tables developed using the Neher-McGrath equation. Power systems software like ETAP and EDSA use the Neher-McGrath equation, as well as equivalent in an IEC standard.

Conclusion Wiring is a very significant part of our work. One of the basic responsibilities of the electrical engineer or electrician is to ensure electrical installations are safe. Whether as engineering designers, constructors, equipment manufacturers, or maintenance personnel, we have the obligation to ensure that our wiring design and installations are correct according to the Code. It behooves us therefore to make sure that cables we use are properly selected and sized for use.