Cable Size Calculation of 125 KW LT Motor

Motor KW = 125
Pf = 0.8, Efficiency = 94%
System Voltage, V1 = 415
Cable length = 200 m
Load Current = P/(1.732xVxPfxEff) > (P = 3 x Vx I Cos = for three phase
circuits)

= 125000/(1.732x415x0.80.94)
~ 230 A
This is the full load current cable needs to cater in Ideal condition. But in practical
situation, there are several derating factors which need to be considered.
The current rating given for the cables is defined for ambient temp of 40* C. If the ambient
temp is greater than that, cable current carrying capacity derates.
Suppose our cable is in Air laid on cable tray,

Air Temperature
20 25 30 35 40 45 50 55
in Deg.

Normal
1.32 1.25 1.16 1.09 1.00 0.90 0.80 0.80
PVC

De-
Rating HR PVC 1.22 1.17 1.12 1.06 1.00 0.94 0.87 0.80
factors

XLPE 1.20 1.16 1.11 1.06 1.00 0.95 0.88 0.82

Rating factors related to variation in ambient air temperature
Temperature Correction Factor, K1 when cable is in the Air = 0.88 (for 50* Amb temp &
XLPE cable)
Grouping of cables also derates cables current carrying capacity. If many cables are
grouped together, they will all heat up. The heat wont be able to dissipate properly hence
it will warm up the cable itself and those in its contact. This will raise the temperature
further. Hence we have to derate the current carrying capacity of the cable according to
the grouping factor.
Lets go for worst case scenario, i.e. 3 trays parallel to each other having 9 cables each
touching to each other.
 No. cables No. of
of No. of per cables
racks rack per rack

1 2 3 6 9 1 2 3 6 9

1 1.00 0.98 0.96 0.93 0.92 1.00 0.84 0.80 0.75 0.73

2 1.00 0.95 0.93 0.90 0.89 1.00 0.80 0.76 0.71 0.69

3 1.00 0.94 0.92 0.89 0.88 1.00 0.78 0.74 0.70 0.68

6 1.00 0.93 0.90 0.87 0.86 1.00 0.76 0.72 0.65 0.66
Cable Grouping Factor (No of Tray Factor), K2 = 0.68 (for 3 trays having 9 cable each)
Total derating factor = K1 x K2
= 0.880.68 = 0.5984
Lets select 1.1 KV, 3 core, 240 Sq.mm, Aluminum, XLPE, Armored cable for single run
Click to enlarge the table

Technical Details For 1.1 KV, 3 Core, Aluminum/Copper Conductor, XLPE Insulated,
Armored Cables
Current capacity of 240 Sq.mm XLPE Armored aluminum cable in Air is 402 Amp
Total derating current of 240 Sq.mm Cable = 4020.5984 = 240.55 Amp
Resistance = 0.162 /Km and
Reactance = 0.072 /Km
 Estimated Voltage Drops in PVC/XLPE Aluminum Cables For A.C. System

(Voltage drop Volts/Km/Amps)

Nominal area of
conductor (sq.
P.V.C. Cable XLPE Cable
mm)

Single Three Single

Three System
Phase Phase Phase

1.5 43.44 37.62 46.34 40.13

2.5 29.04 25.15 30.98 26.83

4 17.78 15.40 18.98 16.44

6 11.06 9.58 11.80 10.22

10 7.40 6.41 7.88 6.82

16 4.58 3.97 4.90 4.24

25 2.89 2.50 3.08 2.67

35 2.10 1.80 2.23 1.94

50 1.55 1.30 1.65 1.44

70 1.10 0.94 1.15 1.00

95 0.79 0.68 0.83 0.70

120 0.63 0.55 0.66 0.56

150 0.52 0.46 0.55 0.48

185 0.42 0.37 0.44 0.40

240 0.34 0.30 0.35 0.30

300 0.28 0.26 0.30 0.26

400 0.24 0.22 0.24 0.22

500 0.23 0.20 0.23 0.20

630 0.20 0.18 0.21 0.18

 800 0.19 0.20

1000 0.18 0.18

Voltage drop, V2 = 0.3 Volts/Km/Amp (as per Havells brochure)
= 0.3x217x200/1000
= 13 V
Terminal voltage at Motor, V2 = 415-13 = 402 V
% Drop = (V2 V1)/(V1)
= (415 402)x100/(415)
= 3.13%
To decide 240 Sq.mm cable, cable selection condition should be checked
1. Cable derating Amp (240.55 Amp)is higher than full load current of load (230 Amp)
= OK
2. Cable voltage Drop (3.13%)is less than defined voltage drop (10%) = OK
3. Cable short circuit capacity (22.56 KA) is higher than system short circuit capacity at
that point ( X KA) = OK
240 Sq.mm cable satisfied all three condition, so it is advisable to use 3 Core 240
Sq.mm cable.

Cable Size Calculation for 350 KW HT Motor

In case of LV system cable can be selected on the basis of its current carrying capacity
and voltage drop but in case of MV/HV system cable short circuit capacity is an
important/deciding factor. So in case of HT motor, the cable short circuit capacity alone
is enough to determine the cable size as rest two parameters will automatically follow.
Consider the below example:
Motor KW = 350
Pf = 0.8, Efficiency = 94%
System Voltage, V1 = 6.6 KV
Cable length = 200 m
Load Current = P/(1.732xVxPfxEff)
= 350000/(1.732x6600x0.80.94)
= 41 A

Suppose Short circuit level/Fault level for H.T. system, Ish (for duration t=1sec) = 26.2 KA
With Aluminum conductor, XLPE insulated cable =

= 278.72 Sq.mm
Hence nearest higher size 300 sq mm is required.
We can see from the below table also that the short circuit capacity of 300sqmm cable is
28 KA which is more than our fault level.
 (6.6KV UNEARTHED / 11KV EARTHED GRADE)

Technical Details For 6.6 KV, 3 Core, Aluminum/Copper Conductor, XLPE Insulated,
Armored Cables
We can see that this will automatically satisfy other two conditions also.
Lets select 6.6 KV, 3 core, 300 Sq.mm, Aluminum, XLPE, Armored cable for single run
Temperature Correction Factor, K1 when cable is in the Air = 0.88 (for 50* Amb temp &
XLPE cable)
Cable Grouping Factor (No of Tray Factor), K2 = 0.68 (for 3 trays having 9 cable each)
Total derating factor = K1 x K2 = 0.880.68 = 0.5984
Current capacity of 300 Sq.mm XLPE Armored aluminum cable in Air is 450 Amp
Total derating current of 300 Sq.mm Cable = 4500.5984 = 269.28 Amp
Resistance = 0.130 /Km and
Reactance = 0.0999 /Km
Voltage drop = 0.26 Volts/Km/Amp (as per Havells brochure)
= 0.26x200x41/1000
= 2.132 V
Terminal voltage at Motor, V2 = 6600-2.132 = 6597.868 V
% Drop = (V1 V2)/(V1)
= (6600 6597.8)x100/(6600)
= 0.032%
To decide 300 Sq.mm cable, cable selection condition should be checked
1. Cable derating Amp (269.28 Amp) is higher than full load current of load (41 Amp)
= OK
2. Cable voltage Drop (0.032%)is less than defined voltage drop (5%) = OK
3. Cable short circuit capacity (28.20 KA) is higher than system short circuit capacity at
that point (26.2 KA) = OK
300 Sq.mm cable satisfied all three condition, so it is advisable to use 3 Core 300
Sq.mm cable.