03/18/2008

Project n° - Unit Eng. code Serial n° Rev. Page

8942V 00 CN 16 12 007 1 2/15

AL-SHAHEEN REFINERY FEED PROJECT
CALCULATION NOTE FOR ELECTRICAL LOW VOLTAGE CABLE SIZING

CONTENTS

1. SCOPE OF THIS DOCUMENT ................................................................................................. 3

2. PURPOSE OF CALCULATION ................................................................................................ 3

3. SPECIFICATIONS, CODE AND STANDARDS ........................................................................ 3

3.1 APPLICABLE PROJECT SPECIFICATION .................................................................................... 3

3.2 CODES AND STANDARDS .............................................................................................................. 3

4. TERMINOLOGY ........................................................................................................................ 4

5. ATMOSPHERIC AND GENERAL DESIGN PARAMETERS .................................................... 4

6. ELECTRICAL SYSTEM DETAILS ............................................................................................ 4

7. VOLTAGE GRADE OF CABLES.............................................................................................. 4

8. CABLE INSTALLATION ........................................................................................................... 5

9. SIZING CALCULATIONS ......................................................................................................... 5

9.1 MAXIMUM ADMISSIBLE CONDUCTOR TEMPERATURE........................................................... 5

9.2 SHORT CIRCUIT CALCULATION................................................................................................... 6
9.3 CORRECTION FACTORS ................................................................................................................ 7
9.4 VOLTAGE DROP CALCULATION .................................................................................................. 7

10. CABLE SIZE SELECTION........................................................................................................ 8

APPENDICES

APPENDIX-1 APPLICABLE TABLES FROM IEC 60364-5-52

APPENDIX-2 RESISTANCE AND REACTANCE OF CABLES

APPENDIX-3 TABLE OF SHORT CIRCUIT RATINGS OF CABLES

APPENDIX-4 240V CABLE SELECTION CHART

APPENDIX-5 110V DC CABLE SELECTION CHART

 Project n° - Unit Eng. code Serial n° Rev. Page

8942V 00 CN 16 12 007 1 3/15

AL-SHAHEEN REFINERY FEED PROJECT
CALCULATION NOTE FOR ELECTRICAL LOW VOLTAGE CABLE SIZING

1. SCOPE OF THIS DOCUMENT

This document defines the technical basis, parameters and criteria used for determining
the required sizes of electrical Low Voltage Cables for the Al-Shaheen Refinery Feed
Project for the QATAR PETROLEUM.

This cable sizing calculation shall be verified and updated based on actual cable
installation details by the EPC Contractor.

2. PURPOSE OF CALCULATION

The purpose of the cable sizing calculation is to determine minimum cable sizes required
to satisfy normal operating load currents, ability to withstand excess currents under power
system short circuit fault conditions and to ensure maintenance of minimum voltage
levels at the equipment under normal operating and motor starting conditions.

3. SPECIFICATIONS, CODE AND STANDARDS

3.1 APPLICABLE PROJECT SPECIFICATION

8942V-00-JSD-16-17-001 Specification for Design Basic Electrical Design

8942V-00-JSS-16-17-002 Specification for cable and wire

8942V-00-DW-16-11-001 General One line diagram

8942V-00-DW-16-31-001 Main cable routing

3.2 CODES AND STANDARDS

The following recommendations are used for different parameters.

IEC 60228 : Conductors of insulated cables

IEC 60502 : Power cables with extruded insulation and their

accessories for rated voltages from 1 kV (Um = 1,2
kV) up to 30 kV (Um = 36 kV)

IEC 60364 Part 5 - 52 : Electrical installation of buildings- Selection and

erection of electrical equipment wiring system.

BICC Catalogue : For typical rating factor

 Project n° - Unit Eng. code Serial n° Rev. Page

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CALCULATION NOTE FOR ELECTRICAL LOW VOLTAGE CABLE SIZING

4. TERMINOLOGY

Abbreviation Definition

AWA Aluminium Wire Armoured

DOL Direct On Line

IEC International Electro-technical Commission

PVC Polyvinyl Chloride

VSDS Variable Speed Drive System

XLPE Cross Linked Polyethylene

SWA Steel Wire Armoured

5. ATMOSPHERIC AND GENERAL DESIGN PARAMETERS

The atmosphere and other design parameters applicable for the project are listed below:
:
Max. ambient temperature 50°C
:
Design ambient temperature for cables in air 50°C
:
Design ambient temperature for cables in concrete 40°C
trench, sand-filled

Design ambient temperature for cables laid directly : 40°C

buried in the ground

Soil Thermal Resistivity : 2.5°K.m/W

( As per Doc No.8942V-00-JSD-1617-001 titled:
“Job Specification for Design Basic Electrical Design”)

6. ELECTRICAL SYSTEM DETAILS

1 Electrical LV supply voltage 240V, 1 ph, 2 wires

110V DC & 24V DC

2 Frequency 50Hz +/- 5 %

7. VOLTAGE GRADE OF CABLES

Low Voltage cables shall be rated for 600/1000 volts.

 Project n° - Unit Eng. code Serial n° Rev. Page

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CALCULATION NOTE FOR ELECTRICAL LOW VOLTAGE CABLE SIZING

8. CABLE INSTALLATION

The methods of cable installations shall be as per “Job specification for Design Basic
Electrical Design “8942V-00-JSD-1617-001

9. SIZING CALCULATIONS

Cables shall be sized in accordance with the following criteria and the relevant standards
listed in this document.

♦ Admissible current ampacity of cables including derating factors.

♦ Admissible voltage drop

♦ Short circuit ratings of supply system and through fault condition of protective devices

9.1 MAXIMUM ADMISSIBLE CONDUCTOR TEMPERATURE

The maximum conductor operating temperature for XLPE insulated cables is considered
as 90°C as per IEC.

9.1.1 REFERENCE CONTINUOUS CURRENT CARRYING AMPACITIES

The current carrying capacities for XLPE cables as shown in Appendix-1 (IEC 60364-5-
52) are used for calculation with the following parameters
Ambient air temperature : 30°C

Ground thermal resistivity : 2.5°K.m/W

Ground temperature : 20°C

Depth of laying (LV Cables) : Up to 0.8m

Max. Conductor Operating temperature : 90°C

The current carrying capacities for XLPE cables as shown in Appendix-1 referred in
IEC60364 are used for calculation

9.1.2 RESISTANCE AND REACTANCE OF CABLES

The Appendix – 2 gives the resistance and reactances of various sizes of cables.
 Project n° - Unit Eng. code Serial n° Rev. Page

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9.2 SHORT CIRCUIT CALCULATION

9.2.1 FEEDER MINIMUM CROSS SECTION BASED ON SHORT CIRCUIT LEVEL

The cable short circuit current capacity is evaluated as

K 2S 2 φ +β 
log e  1 
2
I SC =
T  φ0 + β 

Where : Isc = Symmetrical short circuit current (r.m.s) in Amp

T = duration of short-circuit in second

K = Constant for the material of conductor

S = area of conductor in mm²

∅1 = final temperature in °C

∅0 = initial temperature in °C

β = reciprocal of the temperature coefficient of resistance of

conductor in °C at 0°C

The constant K and β for copper cables and ∅1 and ∅0 for Copper / XLPE cables are:
K = 226

β = 234.5

∅1 = 250°C (for XLPE cable)

∅0 = 90°C (for XLPE cable)

The short circuit currents for Copper /XLPE cables based on above are given as:
143 × S
I SC =
T

Minimum XLPE insulated cable size to satisfy short circuit withstand is determined by the
following formulae:

I SC × T
S=
143
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AL-SHAHEEN REFINERY FEED PROJECT
CALCULATION NOTE FOR ELECTRICAL LOW VOLTAGE CABLE SIZING

Based on above, the short-circuit withstand of cables shall be calculated based on

switchboard short circuit rating and fault clearing time.

The Copper/XLPE cable size required for various short circuit current and clearance
times are as given in Appendix -3.

9.3 CORRECTION FACTORS

Tables A.52-15, A.52-16 & A.52-18 in IEC 60364 Part 5-52 give the various Correction
Factors under different conditions like variation of Ground temperature, Soil thermal
resistivity, grouping of cables and Variation in Ambient temperature.
Based on the installation conditions, the following derating factors have been considered.
For LV cables (laid in ground) as per Appendix -1

a) Rating factor for ground temperature of 40°C = Kt = 0.85

b) Rating factor for soil thermal resistivity of 2.5 °K.m/W = Ks = 1.00

c) Rating factor for direct burial at a depth of 0.8 metre = K1 = 0.96

d) Rating factor for grouping of cables (6 circuit with 1 D spacing) = Kg = 0.55

e) Overall admissible ampacity correction factor Df = Kt X Ks X K1 X Kg = 0.45

Note: As per the Electrical design basic “Cable shall be installed underground throughout
the plant facility.” Therefore 0.45 correction factor is used in this document.

9.4 VOLTAGE DROP CALCULATION

9.4.1 GENERAL MAXIMUM ALLOWABLE VOLTAGE DROP

The following break down to be considered as per Doc No. 8942V-00-JSD-1617-001, sec
6.4

a) Outgoing single phase AC feeders : 5%

b) Outgoing feeders from DC power supply unit : 5%

c) Outgoing feeders from AC power supply unit : 5%

 Project n° - Unit Eng. code Serial n° Rev. Page

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CALCULATION NOTE FOR ELECTRICAL LOW VOLTAGE CABLE SIZING

9.4.2 FORMULA FOR CALCULATING FEEDER VOLTAGE DROP

2
∆V = (R.Cosϕ + XSinϕ ).I .L × 100 (For 1 ph loads)
n x 1000 × V
2
∆V = R.I .LX 100 (For DCloads)
n x 1000 × V

Where : ∆V = Voltage drop (%)

L = Length of cable route in metres

n = Number of cables running in parallel per phase

R = Resistance in Ohm/km @50Hz

X = Reactance in Ohm/km @ 50Hz

l = Carried current in Amps

Cosϕ = Load Power factor

V = Nominal voltage (volts)

10. CABLE SIZE SELECTION

The cable sizing shall be based on selection of the largest cable size meeting the
following requirement

- Short circuit capacity requirements as discussed in section 9.2 and Appendix -3.

- Correction factor as discussed in sections 9.3

- Voltage drop and current carrying capacity requirements as discussed in sections

9.4.

- Cable specification
 Project n° - Unit Eng. code Serial n° Rev. Page

8942V 00 CN 16 12 007 1 9/15

AL-SHAHEEN REFINERY FEED PROJECT
CALCULATION NOTE FOR ELECTRICAL LOW VOLTAGE CABLE SIZING

APPENDIX - 1

APPLICABLE TABLES FROM IEC 60364 -5- 52

(6 PAGES)
LEGEND SHEET FOR INSTALLATION METHODS OF CABLE
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Rating Factor for Depth Of Laying

Depth of (From BICC Cat.)

laying (Metre)
Up to 70 mm2 to
50 mm2 300 mm2

0.5 1.00 1.00

0.6 0.99 0.98

0.8 0.97 0.96

1.0 0.95 0.94

1.25 0.94 0.92

1.5 0.93 0.89

 Project n° - Unit Eng. code Serial n° Rev. Page

8942V 00 CN 16 12 007 1 10/15

AL-SHAHEEN REFINERY FEED PROJECT
CALCULATION NOTE FOR ELECTRICAL LOW VOLTAGE CABLE SIZING

APPENDIX - 2

RESISTANCE AND REACTANCE OF CABLES

(1 PAGE)
 Project n° - Unit Eng. code Serial n° Rev. Page

8942V 00 CN 16 12 007 1 11/15

AL-SHAHEEN REFINERY FEED PROJECT
CALCULATION NOTE FOR ELECTRICAL LOW VOLTAGE CABLE SIZING

TABLE - 1 RESISTANCE AND REACTANCE OF LV CABLE:

Nominal area Resistance (Ref. Table II, column-8 of Reactance at 50 Hz(Ref.

of IEC 60228) Cable manufacturer catalogue)
Conductor R in ohm/km Single core Multi core
2 X in Ohm/km X in Ohm/km
(mm ) 20°C 90°C (ref. Note 1)

2.5 7.41 9.50 - 0.105

4 4.61 5.91 - 0.098
6 3.08 3.95 - 0.094
10 1.83 2.35 - 0.088
16 1.15 1.47 0.118 0.084
25 0.727 0.93 0.112 0.083
35 0.524 0.67 0.107 0.081
50 0.387 0.50 0.104 0.080
70 0.268 0.34 0.101 0.079
95 0.193 0.25 0.098 0.077
120 0.153 0.20 0.096 0.077
150 0.124 0.16 0.096 0.077
185 0.0991 0.13 0.096 0.077
240 0.0754 0.10 0.094 0.077
300 0.0601 0.08 0.093 0.077
400 0.0470 0.06 0.093 0.076
500 0.0366 0.047 0.093 -
630 0.0283 0.036 0.090 -
800 0.0221 0.0283 0.092 -

Notes: 1) The temperature correction factor for copper conductor

254.5
= (Ref. IEC 60 228, cl. 6)
234.5 + t
= 0.78 (t = for 90°C)
 Project n° - Unit Eng. code Serial n° Rev. Page

8942V 00 CN 16 12 007 1 12/15

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CALCULATION NOTE FOR ELECTRICAL LOW VOLTAGE CABLE SIZING

APPENDIX - 3

SHORT CIRCUIT RATING OF CABLES

(1 PAGE)
 Project n° - Unit Eng. code Serial n° Rev. Page

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TABLE – 3 SHORT CIRCUIT RATING OF CABLES

short circuit current

Cu / XLPE cable Size in sq.mm for durations
in ampere
0.01 0.025 0.050 0.100 0.200 0.500 1.000
sec. sec. sec. sec. sec. sec. sec.
52500 50 70 95 120 185 300 400
50000 50 70 95 120 185 300 400
40000 35 50 70 95 150 240 300
31500 25 35 50 70 120 185 240
25000 25 35 50 70 95 150 185
15000 16 16 25 35 50 95 120
10000 10 16 16 25 35 50 70
5000 6 6 10 16 16 25 35
2500 2.5 4 4 6 10 16 25
 Project n° - Unit Eng. code Serial n° Rev. Page

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APPENDIX - 4

240V CABLE SELECTION CHART (POWER FEEDER IN GROUND)

(1 PAGE)
APPENDIX - 4 : CABLE SELECTION CHART FOR 240 V POWER FEEDERS ( LAID IN GROUND )
Rating factor for ground temperature of 40 deg C = 0.85
System voltage (Line to Line) = 0.240 kV Rating factor for soil thermal resistivity of 2.5 Km/W = 1.00
Voltage drop limit= 5% Rating factor for direct burial at a depth of 0.8m = 0.96
DERATING FACTOR = 0.45 Rating factor for grouping of cables (6 circuits, 1D spacing) = 0.55
CABLES HAVING COPPER CONDUCTORS Overall admissible ampacity correction factor = 0.85X1X0.96X0.55 = 0.45
Design Margin = 10%
CABLE SIZE IN mm 2 4 6 10 16 25 35 50 70 95 120 150 185 240 120 150 185 240
No. of Cable cores 4C 4C 4C 4C 4C 4C 4C 4C 4C 4C 4C 4C 4C 4C 4C 4C 4C
No. of Runs per phase 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2
STANDARD CABLE RATING 44 56 73 95 121 146 173 213 252 287 324 363 419 574 648 726 838
SITE CABLE RATING 19.7 25.1 32.8 42.6 54.3 65.5 77.6 95.6 113.1 128.8 145.4 162.9 188.0 257.6 290.8 325.8 376.1
CABLE RESISTANCE IN OHM / km 5.91 3.95 2.35 1.47 0.93 0.67 0.50 0.34 0.25 0.20 0.16 0.13 0.10 0.10 0.08 0.07 0.05
CABLE REACTANCE IN OHM / km 0.098 0.094 0.088 0.084 0.083 0.081 0.080 0.079 0.077 0.077 0.077 0.077 0.077 0.039 0.039 0.039 0.039
FEEDER FEEDER
RATING COS Ø F.L.C MAXIMUM PERMISSIBLE ROUTE LENGTH IN METRE (3000m)
kW AMPS
0.25 0.80 1.30 875 1302 2167 3416 5277 7166 9351 13116 17015 20316 24048 27890 33194 40631 48095 55780 66388
0.30 0.80 1.56 729 1085 1806 2846 4398 5971 7792 10930 14179 16930 20040 23242 27662 33859 40079 46483 55323
0.35 0.80 1.82 625 930 1548 2440 3769 5118 6679 9368 12154 14511 17177 19921 23710 29022 34354 39843 47420
0.50 0.80 2.60 438 651 1084 1708 2639 3583 4675 6558 8507 10158 12024 13945 16597 20316 24048 27890 33194
0.65 0.80 3.39 337 501 834 1314 2030 2756 3596 5044 6544 7814 9249 10727 12767 15627 18498 21454 25534
0.90 0.80 4.69 243 362 602 949 1466 1990 2597 3643 4726 5643 6680 7747 9221 11286 13360 15494 18441
1.25 0.80 6.51 175 260 433 683 1055 1433 1870 2623 3403 4063 4810 5578 6639 8126 9619 11156 13278
3.00 0.80 15.63 73 109 181 285 440 597 779 1093 1418 1693 2004 2324 2766 3386 4008 4648 5532
5.00 0.80 26.04 0 0 108 171 264 358 468 656 851 1016 1202 1395 1660 2032 2405 2789 3319
7.50 0.80 39.06 0 0 0 0 176 239 312 437 567 677 802 930 1106 1354 1603 1859 2213
9.50 0.80 49.48 0 0 0 0 0 189 246 345 448 535 633 734 874 1069 1266 1468 1747
10.00 0.80 52.08 0 0 0 0 0 179 234 328 425 508 601 697 830 1016 1202 1395 1660
15.00 0.80 78.13 0 0 0 0 0 0 0 219 284 339 401 465 553 677 802 930 1106
20.00 0.80 104.17 0 0 0 0 0 0 0 0 0 254 301 349 415 508 601 697 830
25.00 0.80 130.21 0 0 0 0 0 0 0 0 0 0 240 279 332 406 481 558 664
30.00 0.80 156.25 0 0 0 0 0 0 0 0 0 0 0 0 277 339 401 465 553
35.00 0.80 182.29 0 0 0 0 0 0 0 0 0 0 0 0 0 290 344 398 474
40.00 0.80 208.33 0 0 0 0 0 0 0 0 0 0 0 0 0 254 301 349 415
45.00 0.80 234.38 0 0 0 0 0 0 0 0 0 0 0 0 0 0 267 310 369
50.00 0.80 260.42 0 0 0 0 0 0 0 0 0 0 0 0 0 0 240 279 332
55.00 0.80 286.46 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 254 302
60.00 0.80 312.50 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 277
65.00 0.80 338.54 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 255
 Project n° - Unit Eng. code Serial n° Rev. Page

8942V 00 CN 16 12 007 1 15/15

AL-SHAHEEN REFINERY FEED PROJECT
CALCULATION NOTE FOR ELECTRICAL LOW VOLTAGE CABLE SIZING

APPENDIX - 5

110V DC CABLE SELECTION CHART (POWER FEEDER IN GROUND)

(1 PAGE)
APPENDIX - 5 : CABLE SELECTION CHART FOR 110 V DC POWER FEEDERS ( LAID IN LAID IN GROUND )

System voltage = 0.110 kV DC

Voltage drop limit= 3%
DERATING FACTOR = 0.45
CABLES HAVING COPPER CONDUCTORS
Design Margin = 10%
CABLE SIZE IN mm 2 2.5 4 6 10 16 25 35 50 70 95 120 150 185 120 150 185 240
No. of Cable cores 2C 2C 2C 2C 2C 2C 2C 2C 2C 2C 2C 2C 2C 2C 2C 2C 2C
No. of Runs per phase 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2
STANDARD CABLE RATING 34 44 56 73 95 121 146 173 213 252 287 324 363 574 648 726 838
SITE CABLE RATING 15.3 19.7 25.1 32.8 42.6 54.3 65.5 77.6 95.6 113.1 128.8 145.4 162.9 257.6 290.8 325.8 376.1
CABLE DC RESISTANCE IN OHM / km 9.00 5.63 3.75 2.25 1.41 0.90 0.64 0.45 0.32 0.24 0.19 0.15 0.12 0.09 0.08 0.06 0.05
FEEDER FEEDER
RATING COS Ø F.L.C MAXIMUM PERMISSIBLE ROUTE LENGTH IN METRE (3000m)
kW AMPS
0.10 0.80 1.14 161 258 387 645 1032 1612 2257 3225 4515 6128 7741 9676 11934 15482 19352 23868 30964
0.30 0.80 3.41 53 86 129 215 344 537 752 1075 1505 2042 2580 3225 3978 5160 6450 7956 10321
0.50 0.80 5.68 32 51 77 129 206 322 451 645 903 1225 1548 1935 2386 3096 3870 4773 6192
0.70 0.80 7.95 23 36 55 92 147 230 322 460 645 875 1105 1382 1704 2211 2764 3409 4423
0.90 0.80 10.23 17 28 43 71 114 179 250 358 501 680 860 1075 1326 1720 2150 2652 3440
1.10 0.80 12.50 14 23 35 58 93 146 205 293 410 557 703 879 1084 1407 1759 2169 2814
3.60 0.80 40.91 4 7 10 17 28 44 62 89 125 170 215 268 331 430 537 663 860
6.10 0.80 69.32 2 4 6 10 16 26 37 52 74 100 126 158 195 253 317 391 507
8.60 0.80 97.73 1 3 4 7 12 18 26 37 52 71 90 112 138 180 225 277 360
11.10 0.80 126.14 1 2 3 5 9 14 20 29 40 55 69 87 107 139 174 215 278
13.60 0.80 154.55 1 1 2 4 7 11 16 23 33 45 56 71 87 113 142 175 227
16.10 0.80 182.95 1 1 2 4 6 10 14 20 28 38 48 60 74 96 120 148 192
18.60 0.80 211.36 0 1 2 3 5 8 12 17 24 32 41 52 64 83 104 128 166
21.10 0.80 239.77 0 1 1 3 4 7 10 15 21 29 36 45 56 73 91 113 146
23.60 0.80 268.18 0 1 1 2 4 6 9 13 19 25 32 41 50 65 82 101 131
26.10 0.80 296.59 0 0 1 2 3 6 8 12 17 23 29 37 45 59 74 91 118
28.60 0.80 325.00 0 0 1 2 3 5 7 11 15 21 27 33 41 54 67 83 108
31.10 0.80 353.41 0 0 1 2 3 5 7 10 14 19 24 31 38 49 62 76 99
33.60 0.80 381.82 0 0 1 1 3 4 6 9 13 18 23 28 35 46 57 71 92
36.10 0.80 410.23 0 0 1 1 2 4 6 8 12 16 21 26 33 42 53 66 85
38.60 0.80 438.64 0 0 1 1 2 4 5 8 11 15 20 25 30 40 50 61 80
41.10 0.80 467.05 0 0 0 1 2 3 5 7 10 14 18 23 29 37 47 58 75
43.60 0.80 495.45 0 0 0 1 2 3 5 7 10 14 17 22 27 35 44 54 71