POWER SYSTEM DESIGN FOR A

2000 MTPD CEMENT FINISHING PLANT

CHAPTER 5.0:

BRANCH CIRCUIT DESIGN COMPUTATIONS

5.1 THE NEW CEMENT FINISHING PLANT LOADS

Before any design computations can be made, it is important to

establish the connected loads of the New Cement Finishing Plant. From the
technical documents submitted by Taiheiyo Engineering Corporation (TEC) of
Japan, the following are the connected loads.

Table 5.1: GROUP I: THE 4.16 KV MOTOR LOADS

MOTOR EQUPT DESCRIPTION KW RATED RATED AMPS

No.: ID VOLTS
MVM:1 7K11-M1 Cement Mill Main Drive 2,250 4160 V 312 A
MVM:2 7K48-M1 Mill Exhaust Fan 390.0 4160 V 62.5 A

Totals 2,640 4160 V 374.5 A

Table 5.2: GROUP II: THE 46O V MOTOR LOADS

MOTOR EQPT ID DESCRIPTION KW RATED RATED

No.: VOLTS AMPS
1M:1 7K48–M1-H Heater for Exhaust Fan Motor 0.190 460 0.43
1M:2 7K11- M1-H Heater for Mill Motor 0.40 460 1.20
1M:3 7K11-M2 Inlet Lubrication Oil Pump (Low) 2.20 460 4.50
1M:4 7K11-M3 Outlet Lubrication Oil Pump (Low) 2.20 460 4.50
1M:5 7K11-M4 Inlet Lubrication Oil Pump (High) 0.75 460 2.00
1M:6 7K11-M5 Outlet Lubrication Oil Pump (High) 0.75 460 2.00
1M:7 7K15-M2 Bucket Elevator Inching Drive 2.20 460 4.20
1M:8 7K21-M1 Separator Fan Drive (Power Supply) 280 460 367
1M:9 7K28-M1 Rotary Screen Drive 2.20 460 4.20
1M:10 7K36-M1 Rotary Feeder Drive 3.70 460 6.60
1M:11 7K36-M2 Rotary Feeder Drive 3.70 460 6.60

5-1

POWER SYSTEM DESIGN FOR A

2000 MTPD CEMENT FINISHING PLANT

___________________________________________________________________
POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 Table 5.2: GROUP II: THE 46O V MOTOR LOADS (continued…)

MOTOR EQPT ID DESCRIPTION KW RATED RATED

No.: VOLTS AMPS
1M:12 7K36-M3 Rotary Feeder Drive 3.70 460 6.60
1M:13 7K36-M4 Rotary Feeder Drive 3.70 460 6.60
1M:14 7K47-M1 Actuator Damper Drive 0.20 460 0.64
Instruments Power Supply 2.00 460 5.00
Future 30.0 460 50.0

Totals 337.89 460 472.07

Table 5.3: GROUP III: THE 46O V MOTOR LOADS

MOTOR EQPT ID DESCRIPTION KW RATED RATED

No.: VOLTS AMPS
2M:1 7K11-M6 Lubrication Pump for Gear Reducer 5.50 460 10.5
2M:2 7K11-M7 Mill Inching Drive 37.5 460 65.0
2M:3 7K04-M1 Weighing Feeder Drive 3.70 460 7.00
2M:4 7K07-M1 Sealing Air Fan for Water Spray 3.70 460 6.30
2M:5 7K08-M1 Water Spray Pump 4.00 460 6.50
2M:6 7K08-M2 Water Spray Pump 4.00 460 6.50
2M:7 7K15-M1 Bucket Elevator Main Drive 55.0 460 84.4
2M:8 7K17-M1 Air Slide Fan Drive 5.50 460 9.30
2M:9 7K34-M1 Screw Conveyor Drive 5.50 460 9.60
2M:10 7K34-M2 Screw Conveyor Drive 5.50 460 9.60
2M:11 7K34-M3 Screw Conveyor Drive 5.50 460 9.60
2M:12 7K34-M4 Screw Conveyor Drive 5.50 460 9.60
2M:13 7K35-M1 Electric Hoist 5.50 460 7.40
2M:14 7K42-M1 Air Slide Fan Drive 5.50 460 9.30
Air Conditioning Units 55.0 460 78.0
Instruments Power Supply 2.00 460 5.00
Future 30.0 460 50.0

Totals 238.9 460 383.6

5-2

POWER SYSTEM DESIGN FOR A

2000 MTPD CEMENT FINISHING PLANT

5.2 SAMPLE BRANCH CIRCUIT CALCULATIONS (LV Motors)

Table 5.4: MOTOR BRANCH CIRCUIT COMPUTATION, 7K11-M2 Motor

Item CALCULATIONS REMARKS

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POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 1M:3: INLET LUBRICATION OIL PUMP DRIVE (LOW): 2.2 KW, 460 V, SQUIRREL CAGE IM

1 2.2 kW at 460 V, 3-phase, SCIM Original Specification

Controller: FVNR (Full Voltage Non-Reversing)
2 Full Load Amperes = 4.8 A PEC Table 4.30.14.4 (mandatory)

3 Branch Circuit Conductors PEC Art. 2.10.1.1/4.30.2.2 (a)

1.25 x 4.8 = 6 Amps (mandatory)
4 Wire Size at 6 A: Use 3.5 mm sq. THW, 75 deg C PEC Table 3.10.1.16
(Ampacity: 25A)
5 Magnetic Starter: NEMA Size1 FVNR Manufacturer’s Catalog
(NEMA Guide)
6 Branch Circuit Breaker: 250% x 4.8 A = 12 Amp PEC Art. 4.30.4.2 /
(maximum), USE: 15 AT, 3P, 480 V Table 4.30.14.6
7 Branch Circuit Breaker Frame: 100 Amp, but KAIC rating See manufacturer’s Catalog to suit
must be established in separate calculations short circuit rating with fault duty
8 Motor-running protection: 4.8 x 115% = 5.5 Amps. PEC 4.30.3.2a1, PEC Art. 4.30.3.4
OLR setting: 4.8 A to 5.5 A.
9 Conduit for Motor Conductors: 20 mm dia. RSC PEC Appendix C Table C1
(mandatory)
10 Check Voltage Drop, that is 3% for power loads PEC 2.10.2.1, FPN No.4

10a Volts Drop = IR Drop = Amps x L x R x 1.732 L = length in M, R = resistance per

Volts Drop = 4.8 x 90 x 2.05/305 x 1.732 = 5.03 V M, PEC Table 9.1.1.8
10b % VD = (5.03 x 100) / 460 = 1.09 % at normal power OK. Below the 3% requirement
factor

5-3

POWER SYSTEM DESIGN FOR A

2000 MTPD CEMENT FINISHING PLANT

Table 5.5: MOTOR BRANCH CIRCUIT COMPUTATION, 7K11-M3 Motor

Item CALCULATIONS REMARKS

1M:4: OUTLET LUBRICATION OIL PUMP DRIVE (LOW): 2.2 KW, 460 V, SQUIRREL CAGE IM

1 2.2 kW at 460 V, 3-phase, SCIM Original Specification

Controller: FVNR (Full Voltage Non-Reversing)
2 Full Load Amperes = 4.8 A PEC Table 4.30.14.4 (mandatory)

___________________________________________________________________
POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 3 Branch Circuit Conductors PEC Art. 2.10.1.1/4.30.2.2 (a)
1.25 x 4.8 = 6 Amps (mandatory)
4 Wire Size at 6 A: Use 3.5 mm sq. THW, 75 deg C PEC Table 3.10.1.16
(Ampacity: 25A)
5 Magnetic Starter: NEMA Size1 FVNR Manufacturer’s Catalog
(NEMA Guide)
6 Branch Circuit Breaker: 250% x 4.8 A = 12 Amp PEC Art. 4.30.4.2 /
(maximum), USE: 15 AT, 3P, 480 V Table 4.30.14.6
7 Branch Circuit Breaker Frame: 100 Amp, but KAIC rating See manufacturer’s Catalog to suit
must be established in separate calculations short circuit rating with fault duty
8 Motor-running protection: 4.8 x 115% = 5.5 Amps. PEC 4.30.3.2a1, PEC Art. 4.30.3.4
OLR setting: 4.8 A to 5.5 A.
9 Conduit for Motor Conductors: 20 mm dia. RSC PEC Appendix C Table C1
(mandatory)
10 Check Voltage Drop, that is 3% for power loads PEC 2.10.2.1, FPN No.4

10a Volts Drop = IR Drop = Amps x L x R x 1.732 L = length in M, R = resistance per

Volts Drop = 4.8 x 90 x 2.05/305 x 1.732 = 5.03 V M, PEC Table 9.1.1.8
10b % VD = (5.03 x 100) / 460 = 1.09 % at normal power OK. Below the 3% requirement
factor

5-4

POWER SYSTEM DESIGN FOR A

2000 MTPD CEMENT FINISHING PLANT

Table 5.6: MOTOR BRANCH CIRCUIT COMPUTATION, 7K11-M4 Motor

Item CALCULATIONS REMARKS

1M:5: INLET LUBRICATION OIL PUMP DRIVE (HIGH): 0.75 KW, 460 V, SQUIRREL CAGE IM

1 0.75 kW at 460 V, 3-phase, SCIM Original Specification

Controller: FVNR (Full Voltage Non-Reversing)
2 Full Load Amperes = 2.1 A PEC Table 4.30.14.4
(mandatory)
3 Branch Circuit Conductors PEC Art. 2.10.1.1/4.30.2.2 (a)
1.25 x 2.1 =2. 6 Amps (mandatory)
4 Wire Size at 2.6 A: Use 3C-3.5 mm sq. THW, 75 deg C PEC Table 3.10.1.16
(Ampacity: 25A)
5 Magnetic Starter: NEMA Size1 FVNR Manufacturer’s Catalog
(NEMA Guide)

___________________________________________________________________
POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 6 Branch Circuit Breaker: 250% x 2.1 A = 5.25 Amp PEC Art. 4.30.4.2 /
(maximum), USE: 15 AT, 3P, 480 V Table 4.30.14.6
7 Branch Circuit Breaker Frame: 100 Amp, but KAIC rating See manufacturer’s Catalog to suit
must be established in separate calculations short circuit rating with fault duty
8 Motor-running protection: 2.1 x 115% = 2.4 Amps. PEC 4.30.3.2c1
OLR setting: 2.1 A 2.4 A.
9 Conduit for Motor Conductors: 20 mm dia. RSC PEC Appendix C Table C1
(mandatory)

10 Check Voltage Drop, that is 3% for power loads PEC 2.10.2.1, FPN No.4

10a Volts Drop = IR Drop = Amps x L x R x 1.732 L = length in M, R = resistance per

Volts Drop = 2.1 x 105 x 2.05/305 x 1.732 = 2.57 V M, PEC Table 9.1.1.8
10b % VD = 2.57 x 100) / 460 = 0.55 % at normal power OK. Below the 3% requirement
factor

5-5
5-5
POWER SYSTEM DESIGN FOR A
2000 MTPD CEMENT FINISHING PLANT

Table 5.7: MOTOR BRANCH CIRCUIT COMPUTATION, 7K11-M5 Motor

Item CALCULATIONS REMARKS

1M:6: OUTLET LUBRICATION OIL PUMP DRIVE (HIGH): 0.75 KW, 460 V, SQUIRREL CAGE IM

1 0.75 kW at 460 V, 3-phase, SCIM Original Specification

Controller: FVNR (Full Voltage Non-Reversing)
2 Full Load Amperes = 2.1 A PEC Table 4.30.14.4
(mandatory)
3 Branch Circuit Conductors PEC Art. 2.10.1.1/4.30.2.2 (a)
1.25 x 2.1 =2. 6 Amps (mandatory)
4 Wire Size at 2.6 A: Use 3C-3.5 mm sq. THW, 75 deg C PEC Table 3.10.1.16
(Ampacity: 25A)
5 Magnetic Starter: NEMA Size1 FVNR Manufacturer’s Catalog
(NEMA Guide)
6 Branch Circuit Breaker: 250% x 2.1 A = 5.25 Amp PEC Art. 4.30.4.2 /
(maximum), USE: 15 AT, 3P, 480 V Table 4.30.14.6
7 Branch Circuit Breaker Frame: 100 Amp, but KAIC rating See manufacturer’s Catalog to suit
must be established in separate calculations short circuit rating with fault duty
8 Motor-running protection: 2.1 x 115% = 2.4 Amps. PEC 4.30.3.2c1

___________________________________________________________________
POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 OLR setting: 2.1 A 2.4 A.
9 Conduit for Motor Conductors: 20 mm dia. RSC PEC Appendix C Table C1
(mandatory)

10 Check Voltage Drop, that is 3% for power loads PEC 2.10.2.1, FPN No.4

10a Volts Drop = IR Drop = Amps x L x R x 1.732 L = length in M, R = resistance per

Volts Drop = 2.1 x 105 x 2.05/305 x 1.732 = 2.57 V M, PEC Table 9.1.1.8
10b % VD = 2.57 x 100) / 460 = 0.55 % at normal power OK. Below the 3% requirement
factor

5-6
POWER SYSTEM DESIGN FOR A 5-6
2000 MTPD CEMENT FINISHING PLANT

Table 5.8: MOTOR BRANCH CIRCUIT COMPUTATION, 7K15-M2 Motor

Item CALCULATIONS REMARKS

1M:7: BUCKET ELEVATOR INCHING DRIVE: 2.2 KW, 460 V, SQUIRREL CAGE IM

1 2.2 kW at 460 V, 3-phase, SCIM Original Specification

Controller: FVNR (Full Voltage Non-Reversing)
2 Full Load Amperes = 4.8 A PEC Table 4.30.14.4 (mandatory)

3 Branch Circuit Conductors PEC Art. 2.10.1.1/4.30.2.2 (a)

1.25 x 4.8 = 6 Amps (mandatory)
4 Wire Size at 6 A: Use 3.5 mm sq. THW, 75 deg C PEC Table 3.10.1.16
(Ampacity: 25A)
5 Magnetic Starter: NEMA Size1 FVNR Manufacturer’s Catalog
(NEMA Guide)
6 Branch Circuit Breaker: 250% x 4.8 A = 12 Amp PEC Art. 4.30.4.2 /
(maximum), USE: 15 AT, 3P, 480 V Table 4.30.14.6
7 Branch Circuit Breaker Frame: 100 Amp, but KAIC rating See manufacturer’s Catalog to suit
must be established in separate calculations short circuit rating with fault duty
8 Motor-running protection: 4.8 x 115% = 5.5 Amps. PEC 4.30.3.2a1, PEC Art. 4.30.3.4
OLR setting: 4.8 A to 5.5 A.
9 Conduit for Motor Conductors: 20 mm dia. RSC PEC Appendix C Table C1
(mandatory)
10 Check Voltage Drop, that is 3% for power loads PEC 2.10.2.1, FPN No.4

10a Volts Drop = IR Drop = Amps x L x R x 1.732 L = length in M, R = resistance per

___________________________________________________________________
POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 Volts Drop = 4.8 x 90 x 2.05/305 x 1.732 = 5.03 V M, PEC Table 9.1.1.8
10b % VD = (5.03 x 100) / 460 = 1.09 % at normal power OK. Below the 3% requirement
factor

5-7

POWER SYSTEM DESIGN FOR A

2000 MTPD CEMENT FINISHING PLANT

TABLE 5.9: MOTOR BRANCH CIRCUIT COMPUTATION, 7K21-M1 Motor

Item CALCULATIONS REMARKS

1M:8: SEPARATOR FAN DRIVE: 280 KW, 460 V, SQUIRREL CAGE IM

(POWER SUPPLY ONLY)
1 280 kW at 460 V, 3-phase, SCIM, VFD Supplied by Process OEM
Controller: VFD (Variable Frequency Drive)
2 Full Load Amperes = 367 A Original Specification from OEM
3 Branch Circuit Conductors: 1.25 x 367 = 459 Amps PEC Art. 2.10.1.1/4.30.2.2
4 Wire Size at 459 A: USE Shielded Cable but Equivalent to 2// PEC Table 3.10.1.16 for wire size.
200 mm sq. THW per phase + ground, Shielded Cable: Requirements for
Ampacity: 660 A; Effective Ampacity( Derated) = 528A Variable Frequency Drives
5 Motor Controller: VSD, 300 KW, but needs manufac-turer’s Manufacturer’s Catalog
catalog to fit application to available models
6 Branch Circuit Breaker: 150% x 367 A =550 Amp *150% of FLA for VSD Drives
(maximum), USE: 600 AT/600 AF, 3P, 600 V Table 4.30.14.6 see note:#3
7 Branch Ckt Breaker Frame: 600 Amp, but KAIC rating must See manufacturer’s Catalog to suit
be established in separate calculations short circuit rating with fault duty

___________________________________________________________________
POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 5-8

POWER SYSTEM DESIGN FOR A

2000 MTPD CEMENT FINISHING PLANT

Table 5.10: MOTOR BRANCH CIRCUIT COMPUTATION, 7K36-M1 Motor

Item CALCULATIONS REMARKS

1M:10: ROTARY FEEDER DRIVE: 3.7 KW, 460 V, SQUIRREL CAGE IM

1 3.7 kW at 460 V, 3-phase, SCIM Original Specification

Controller: FVNR (Full Voltage Non-Reversing)
2 Full Load Amperes = 7.6 A PEC Table 4.30.14.4 (mandatory)

3 Branch Circuit Conductors (From Breaker to Controller): PEC Art. 2.10.1.1/4.30.2.2 (a)
1.25 x 7.6 = 9.5 Amps (mandatory)
4 Wire Size at 9.5 A: Use 3C-3.5 mm sq. THW, 75 deg C PEC Table 3.10.1.16
(Ampacity: 25A)
5 Magnetic Starter: NEMA Size1 FVNR Manufacturer’s Catalog
(NEMA Guide)
6 Branch Circuit Breaker: 250% x 9.6 A = 24 Amp PEC Art. 4.30.4.2 /
(maximum), USE: 20 AT, 3P, 480 V Table 4.30.14.6
7 Branch Circuit Breaker Frame: 100 Amp, but KAIC rating See manufacturer’s Catalog to suit
must be established in separate calculations short circuit rating with fault duty
8 Motor-running protection: 7.6 x 115% = 8.7 Amps. PEC 4.30.3.2a1, PEC Art. 4.30.3.4
OLR setting: 7.6 A to 8.7 A.
9 Conduit for Motor Conductors: 20 mm dia. RSC PEC Appendix C Table C1
(mandatory)

10 Check Voltage Drop, that is 3% for power loads PEC 2.10.2.1, FPN No.4

10a Volts Drop = IR Drop = Amps x L x R x 1.732 L = length in M, R = resistance per

Volts Drop = 7.6 x 85 x 2.05/305 x 1.732 = 7.5 V M, PEC Table 9.1.1.8
10b % VD = (7.5 x 100) / 460 = 1.6 % at normal power OK. Below the 3% requirement
factor

___________________________________________________________________
POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 5-9

5-9

___________________________________________________________________
POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 POWER SYSTEM DESIGN FOR A
2000 MTPD CEMENT FINISHING PLANT

Table 5.11: MOTOR BRANCH CIRCUIT COMPUTATION, 7K36-M2 Motor

Item CALCULATIONS REMARKS

1M:11: ROTARY FEEDER DRIVE: 3.7 KW, 460 V, SQUIRREL CAGE IM

1 3.7 kW at 460 V, 3-phase, SCIM Original Specification

Controller: FVNR (Full Voltage Non-Reversing)
2 Full Load Amperes = 7.6 A PEC Table 4.30.14.4 (mandatory)

3 Branch Circuit Conductors (From Breaker to Controller): PEC Art. 2.10.1.1/4.30.2.2 (a)
1.25 x 7.6 = 9.5 Amps (mandatory)
4 Wire Size at 9.5 A: Use 3C-3.5 mm sq. THW, 75 deg C PEC Table 3.10.1.16
(Ampacity: 25A)
5 Magnetic Starter: NEMA Size1 FVNR Manufacturer’s Catalog
(NEMA Guide)
6 Branch Circuit Breaker: 250% x 9.6 A = 24 Amp PEC Art. 4.30.4.2 /
(maximum), USE: 20 AT, 3P, 480 V Table 4.30.14.6
7 Branch Circuit Breaker Frame: 100 Amp, but KAIC rating See manufacturer’s Catalog to suit
must be established in separate calculations short circuit rating with fault duty
8 Motor-running protection: 7.6 x 115% = 8.7 Amps. PEC 4.30.3.2a1, PEC Art. 4.30.3.4
OLR setting: 7.6 A to 8.7 A.
9 Conduit for Motor Conductors: 20 mm dia. RSC PEC Appendix C Table C1
(mandatory)

10 Check Voltage Drop, that is 3% for power loads PEC 2.10.2.1, FPN No.4

10a Volts Drop = IR Drop = Amps x L x R x 1.732 L = length in M, R = resistance per

Volts Drop = 7.6 x 85 x 2.05/305 x 1.732 = 7.5 V M, PEC Table 9.1.1.8
10b % VD = (7.5 x 100) / 460 = 1.6 % at normal power OK. Below the 3% requirement
factor

5-10
POWER SYSTEM DESIGN FOR A
2000 MTPD CEMENT FINISHING PLANT

___________________________________________________________________
POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 Table 5.12: MOTOR BRANCH CIRCUIT COMPUTATION, 7K36-M3 Motor

Item CALCULATIONS REMARKS

1M:12: ROTARY FEEDER DRIVE: 3.7 KW, 460 V, SQUIRREL CAGE IM

1 3.7 kW at 460 V, 3-phase, SCIM Original Specification

Controller: FVNR (Full Voltage Non-Reversing)
2 Full Load Amperes = 7.6 A PEC Table 4.30.14.4 (mandatory)

3 Branch Circuit Conductors (From Breaker to Controller): PEC Art. 2.10.1.1/4.30.2.2 (a)
1.25 x 7.6 = 9.5 Amps (mandatory)
4 Wire Size at 9.5 A: Use 3C-3.5 mm sq. THW, 75 deg C PEC Table 3.10.1.16
(Ampacity: 25A)
5 Magnetic Starter: NEMA Size1 FVNR Manufacturer’s Catalog
(NEMA Guide)
6 Branch Circuit Breaker: 250% x 9.6 A = 24 Amp PEC Art. 4.30.4.2 /
(maximum), USE: 20 AT, 3P, 480 V Table 4.30.14.6
7 Branch Circuit Breaker Frame: 100 Amp, but KAIC rating See manufacturer’s Catalog to suit
must be established in separate calculations short circuit rating with fault duty
8 Motor-running protection: 7.6 x 115% = 8.7 Amps. PEC 4.30.3.2a1, PEC Art. 4.30.3.4
OLR setting: 7.6 A to 8.7 A.
9 Conduit for Motor Conductors: 20 mm dia. RSC PEC Appendix C Table C1
(mandatory)

10 Check Voltage Drop, that is 3% for power loads PEC 2.10.2.1, FPN No.4

10a Volts Drop = IR Drop = Amps x L x R x 1.732 L = length in M, R = resistance per

Volts Drop = 7.6 x 85 x 2.05/305 x 1.732 = 7.5 V M, PEC Table 9.1.1.8
10b % VD = (7.5 x 100) / 460 = 1.6 % at normal power OK. Below the 3% requirement
factor

5-11

POWER SYSTEM DESIGN FOR A

2000 MTPD CEMENT FINISHING PLANT

___________________________________________________________________
POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 Table 5.13: MOTOR BRANCH CIRCUIT COMPUTATION, 7K36-M4 Motor

Item CALCULATIONS REMARKS

1M:13: ROTARY FEEDER DRIVE: 3.7 KW, 460 V, SQUIRREL CAGE IM

1 3.7 kW at 460 V, 3-phase, SCIM Original Specification

Controller: FVNR (Full Voltage Non-Reversing)
2 Full Load Amperes = 7.6 A PEC Table 4.30.14.4 (mandatory)

3 Branch Circuit Conductors (From Breaker to Controller): PEC Art. 2.10.1.1/4.30.2.2 (a)
1.25 x 7.6 = 9.5 Amps (mandatory)
4 Wire Size at 9.5 A: Use 3C-3.5 mm sq. THW, 75 deg C PEC Table 3.10.1.16
(Ampacity: 25A)
5 Magnetic Starter: NEMA Size1 FVNR Manufacturer’s Catalog
(NEMA Guide)
6 Branch Circuit Breaker: 250% x 9.6 A = 24 Amp PEC Art. 4.30.4.2 /
(maximum), USE: 20 AT, 3P, 480 V Table 4.30.14.6
7 Branch Circuit Breaker Frame: 100 Amp, but KAIC rating See manufacturer’s Catalog to suit
must be established in separate calculations short circuit rating with fault duty
8 Motor-running protection: 7.6 x 115% = 8.7 Amps. PEC 4.30.3.2a1, PEC Art. 4.30.3.4
OLR setting: 7.6 A to 8.7 A.
9 Conduit for Motor Conductors: 20 mm dia. RSC PEC Appendix C Table C1
(mandatory)

10 Check Voltage Drop, that is 3% for power loads PEC 2.10.2.1, FPN No.4

10a Volts Drop = IR Drop = Amps x L x R x 1.732 L = length in M, R = resistance per

Volts Drop = 7.6 x 85 x 2.05/305 x 1.732 = 7.5 V M, PEC Table 9.1.1.8
10b % VD = (7.5 x 100) / 460 = 1.6 % at normal power OK. Below the 3% requirement
factor

5-12
5-12
POWER SYSTEM DESIGN FOR A
2000 MTPD CEMENT FINISHING PLANT

Table 5.14: MOTOR BRANCH CIRCUIT COMPUTATION, 7K47-M1 Motor

Item CALCULATIONS REMARKS

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POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 1M:14: ACTUATOR DAMPER DRIVE: 0.2 KW, 460 V, SQUIRREL CAGE IM

1 0.2 kW at 460 V, 3-phase, SCIM Original Specification

Controller: FVNR (Full Voltage Non-Reversing)
2 Full Load Amperes = 0.64 A Original Specification

3 Branch Circuit Conductors PEC Art. 2.10.1.1/4.30.2.2 (a)

1.25 x 0.64 =0.8 Amps (mandatory)
4 Wire Size at 0.8 A: Use 3C-3.5 mm sq. THW, 75 deg C PEC Table 3.10.1.16
(Ampacity: 25A) (Mandatory)
5 Magnetic Starter: NEMA Size1 FVNR Manufacturer’s Catalog
(NEMA Guide)
6 Branch Circuit Breaker: 250% x 0.8 A = 2.0 Amp PEC Art. 4.30.4.3 a1
(maximum), USE: 15 AT, 3P, 480 V
7 Branch Circuit Breaker Frame: 100 Amp, but KAIC rating See manufacturer’s Catalog to suit
must be established in separate calculations short circuit rating with fault duty
8 Motor-running protection: 0.64 x 115% = 0.7 Amps. PEC 4.30.3.2c1
OLR setting: 0.6A~0.8 A.
9 Conduit for Motor Conductors: 20 mm dia. RSC PEC Appendix C Table C1
(mandatory)

10 Check Voltage Drop, that is 3% for power loads PEC 2.10.2.1, FPN No.4

10a Volts Drop = IR Drop = Amps x L x R x 1.732 L = length in M, R = resistance per

Volts Drop =0.64 x 200 x 2.05/305 x 1.732 = 1.49 V M, PEC Table 9.1.1.8
10b % VD = (1.49 V x 100) / 460 = 0.32 % at normal power OK. Below the 3% requirement
factor

5-13

POWER SYSTEM DESIGN FOR A

2000 MTPD CEMENT FINISHING PLANT

Table 5.15: MOTOR BRANCH CIRCUIT COMPUTATION, 7K11-M6 Motor

Item CALCULATIONS REMARKS

2M:1: LUBRICATION PUMP FOR GEAR REDUCER DRIVE: 5.5 KW, 460 V, SQUIRREL CAGE IM

1 5.5 kW at 460 V, 3-phase, SCIM Original Specification

Controller: FVNR (Full Voltage Non-Reversing)
2 Full Load Amperes = 11 A PEC Table 4.30.14.4 (mandatory)
3 Branch Circuit Conductors PEC Art. 2.10.1.1/4.30.2.2 (a)

___________________________________________________________________
POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 1.25 x 11 = 13.75 Amps (mandatory)
4 Wire Size at 13.75 A: Use 3C-3.5 mm sq. THW, 75 deg C PEC Table 3.10.1.16
(Ampacity: 25A)
5 Magnetic Starter: NEMA Size1 FVNR Manufacturer’s Catalog
(NEMA Guide)
6 Branch Circuit Breaker: 250% x 11 A = 27.5 Amp PEC Art. 4.30.4.2 /
(maximum), USE: 30 AT, 3P, 480 V Table 4.30.14.6
7 Branch Circuit Breaker Frame: 100 Amp, but KAIC rating See manufacturer’s Catalog to suit
must be established in separate calculations short circuit rating with fault duty
8 Motor-running protection: 11 x 115% = 12.65 Amps. PEC 4.30.3.2a1, PEC Art. 4.30.3.4
OLR setting: 11 A to 12 A.
9 Conduit for Motor Conductors: 20 mm dia. RSC PEC Appendix C Table C1
10 Check Voltage Drop, that is 3% for power loads PEC 2.10.2.1, FPN No.4
10a Volts Drop = IR Drop = Amps x L x R x 1.732 L = length in M, R = resistance per
Volts Drop = 11 x 155 x 2.05/305 x 1.732 = 19.8 V M, PEC Table 9.1.1.8
10b % VD = (19.8 x 100) / 460 = 4.3 % at normal power More than 3% requirement
factor
11 Use the next larger conductor # 5.5 mm sq. THW to Engineering Practice
meet voltage drop requirement
11a Check new wire size: IR Drop = 11 x 155 x 1.29/305 x
1.732 = 12.48 volts
11b % VD = (12.48 x 100) / 460 = 2.7 % at normal power Ok below 3% requirement
factor
12 New conduit sized: use 25 mm dia, RSC PEC Appendix C Table C1
(mandatory)

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Table 5.16: MOTOR BRANCH CIRCUIT COMPUTATION, 7K11-M7 Motor

Item CALCULATIONS REMARKS

2M:2: MILL INCHING DRIVE: 37.5 KW, 460 V, SQUIRREL CAGE IM

1 37.5 kW at 460 V, 3-phase, SCIM Original Specification

2 Full Load Amperes = 65 A PEC Table 4.30.14.4 (mandatory)

3 Branch Circuit Conductors (From Breaker to Controller): PEC Art. 2.10.1.1/4.30.2.2

1.25 x 65 = 81 Amps (mandatory)
4 Wire Size at 81 A: Use 3-22.0 mm sq. THW, 75 deg C PEC Table 3.10.1.16
(Ampacity: 85A)
5 Underground Installation: Use minimum of 40 mm Trade Practice
conduit

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POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 6 Magnetic Starter: NEMA Size 2 Wye Delta Manufacturer’s Catalog
(NEMA Guide)
7 Branch Circuit Breaker: 200% x 65 A = 130 Amp PEC Art. 4.30.4.2 /
(maximum), USE: 125 AT, 3P, 480 V Table 4.30.14.6 see note:#3
7a Branch Ckt Breaker Frame: 250 Amp, but KAIC rating See manufacturer’s Catalog to suit
must be established in separate calculations short circuit rating with fault duty
8 Motor-running protection (heaters or adjustable trip in PEC 4.30.3.2a1, PEC Art. 4.30.3.4
controller): (65A/1.732) x 115% = 43 Amps.
OLR setting: 37 A to 43 A.
9 Wire Size from Controller to Motor: Calculating for phase currents to
1.25 x (65/1.732) = 47 A. motor, not the line currents. Also we
Use: 6 – 14 mm sq. THW, Ampacity: 65 Amps. include derating factor for more than
With derating factor of 80% for 6 conductors in a 3 conductors in conduit. PEC
conduit, derated ampacity becomes 52 A which is 3.10.1.15(b)(2)
correct.
10 Conduit for Motor Conductors: 32 mm dia. RSC PEC Appendix C Table C1
(mandatory)

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TABLE 5.17: MOTOR BRANCH CIRCUIT COMPUTATION, 7K04-M1 Motor

Item CALCULATIONS REMARKS

2M:3: WEIGHING FEEDER DRIVE: 3.7 KW, 460 V, SQUIRREL CAGE IM

1 3.7 kW at 460 V, 3-phase, SCIM, Original Specification

Controller: Variable Frequency Drive Controller Supplied by Process OEM
2 Full Load Amperes = 7.6 A PEC Table 4.30.14.4
(mandatory)
3 Branch Circuit Conductors: 1.25 x 7.6 = 9.5 Amps PEC Art. 2.10.1.1/4.30.2.2

4 Wire Size at 9.5 A: USE Shielded Cable but Equivalent to PEC Table 3.10.1.16 for wire size.
three 3.5 mm sq. THW + ground, Ampacity: 20 A Shielded Cable Required for VSD’s
5 Branch Circuit Conduit, RSC: 20mm dia. PEC Tables Appendix C Table C1

6 Underground Installation: Use 25 mm dia. conduit Trade Practice

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POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 7 Motor Controller: VFD, 5.5 KW Minimum, but needs Manufacturer’s Catalog,
manufacturer’s catalog to fit application to available models NEMA Guide
8 Branch Circuit Breaker: 150% x 7.6 A = 11.4 Amp PEC Art. 4.30.4.2 /
USE: 15 AT, 3P, 480 V Table 4.30.14.6 see note:#3
8a Branch Ckt Breaker Frame: 100 Amp, but KAIC rating must See manufacturer’s Catalog to suit
be established in separate calculations short circuit rating with fault duty
9 Motor-running protection: Set at 100%-115% PEC 4.30.3.2a1, PEC Art. 4.30.3.4
Program Setting at VFD: 7.6 A to 8.7 A

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Table 5.18: MOTOR BRANCH CIRCUIT COMPUTATION, 7K15-M1 Motor

Item CALCULATIONS REMARKS

2M:7: BUCKET ELEVATOR DRIVE: 55 KW, 460 V, SQUIRREL CAGE IM

1 55 kW at 460 V, 3-phase, SCIM Original Specification

2 Full Load Amperes = 96 A PEC Table 4.30.14.4

(mandatory)
3 Branch Circuit Conductors: 1.25 x 96 = 120 Amps PEC Art. 2.10.1.1/4.30.2.2
(mandatory)
4 Wire Size at 120 A: Use 3 – 50.0 mm sq. THW, 75 deg C PEC Table 3.10.1.16
Ampacity: 145 A
5 Overhead Installation: Use cable tray Trade Practice

6 Magnetic Starter: NEMA Size 3 Wye Delta (NEMA 3YD) Manufacturer’s Catalog
NEMA Guide
7 Branch Circuit Breaker: 200% x 96 A = 192 Amp PEC Art. 4.30.4.2 /
(maximum), USE: 200 AT, 3P, 480 V Table 4.30.14.6 see note:#3
7a Branch Ckt Breaker Frame: 250 Amp, but KAIC rating See manufacturer’s Catalog to suit
must be established in separate calculations short circuit rating with fault duty
8 Motor-running protection: 96A/1.732 x 115% = 63 A PEC 4.30.3.2a1, PEC Art. 4.30.3.4
OLR Setting: 55 A to 63 A
9 Wire Size from Controller to Motor: 1.25 x (96/1.732) = Derating factor for more than 3
69 A. Use: 6 –22 mm2 THW; Ampacity: 85 Amps. With conductors in conduit. PEC
derating factor of 80% for 6 conductors in a conduit, 3.10.1.15(b)(2)
derated ampacity becomes 68 A which is correct.

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POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
10 Conduit for Motor Conductors: 40 mm dia. RSC PEC Appendix C Table C1

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 POWER SYSTEM DESIGN FOR A
2000 MTPD CEMENT FINISHING PLANT

Table 5.19: MOTOR BRANCH CIRCUIT COMPUTATION, 7K34-M1 Motor

Item CALCULATIONS REMARKS

2M:9: SCREW CONVEYOR DRIVE : 5.5 KW, 460V, SQUIRREL CAGE INDUCTION MOTOR

1 5.5 kW at 460 V, 3-phase , Controller: FVNR Original Specification

2 Full Load Amperes = 9.6 A PEC Table 4.30.14.4 (mandatory)
3 Branch Circuit Conductors: 1.25 x 9.6 = 12.0 Amps PEC Art. 2.10.1.1/4.30.2.2
4 Wire Size at 12.0 A: Use 3/C, 3.5 mm sq. THW PEC Table 3.10.1.16
at 75 deg C (20 A)
5 Conduit, RSC: 15 mm dia. PEC Tables Appendix C Table C1
6 Underground Installation: Use minimum Trade practice
of 20 mm dia. conduit
7 Magnetic Starter: NEMA Size 1 FVNR Manufacturer’s Catalog
8 Branch Circuit Breaker: 250% x 9.6 A = 24 Amp PEC Art. 4.30.4.2 / Table 4.30.14.6
(maximum), USE: 30 AT, 3P, 480V
8a Branch Ckt Breaker Frame: 100 Amp, but KAIC rating See manufacturer’s Catalog to suit
must be established in separate calculations short circuit rating with fault duty
9 Control: 4/C-2.0 mm sq. Trade Practice
10 Motor-running protection (heaters or adjustable trip in PEC 4.30.3.2a1, PEC 430 Art.
controller): 9.6 A x 115% = 11.0 Amps. 4.30.3.4
OLR Setting: 9.6 A to 11.0 A
11 Check Voltage Drop, that is 3% for power loads PEC 2.10.2.1, FPN No.4
11a Volts Drop = IR Drop = Amps x L x R x 1.732 L = length in M, R = resistance per
Volts Drop = 9.6 x 235 x 2.05/305 x 1.732 = 26.26 V M, PEC Table 9.1.1.8

11b % VD = (26.26 x 100) / 460 = 5.7 % at normal P.F.. More than 3% requirement
12 Use the next larger conductor # 5.5 mm sq. THW to meet Engineering Practice
voltage drop requirement
12a Check new wire size: IR Drop = 9.6 x 235 x 1.29/305 x
1.732 = 16.52 volts
12b % VD = (16.52 x 100) / 460 = 3.6 % at normal P. F. Still more than 3% requirement
13 Use again the next larger conductor # 8.0 mm sq. THW to Engineering Practice
meet voltage drop requirement
13a Check new wire size: IR Drop = 9.6 x 235 x 0.809/305 x PEC Table 9.1.1.8
1.732 = 10.36 volts

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POWER SYSTEM DESIGN FOR A 2000 MTPD CEMENT FINISHING PLANT
 Table 5.19: MOTOR BRANCH CIRCUIT COMPUTATION, 7K34-M1 Motor (continued)

13b % VD = (10.36 x 100) / 460 = 2.25 % at normal P. F. Ok less than 3% requirement

14 New conduit sized: use 25 mm dia, RSC PEC Appendix C Table C1

5.3 SAMPLE MOTOR BRANCH CIRCUIT CALCULATIONS (MV Motor)

TABLE 5.20: 4160 V MOTOR BRANCH CIRCUIT COMPUTATION, 7K11-M1 Motor

CALCULATIONS REMARKS
Item

MVM: 1 CEMENT MILL DRIVE, 2,250 KW WOUND ROTOR INDUCTION MOTOR

1 Cement Mill Drive: 2250 kW, 4160 V, Open Drip-Proof Original Specification
Slip Ring Type Induction Motor Process OEM-supplied
2 2250 kW at 4160 V, 3-phase, Original Specification
Motor Controller: Liquid Rheostat Starting Process OEM-supplied
3 Primary Voltage = 4160 V, Primary FLA = 450 A Original Specification
Secondary Voltage = 1,600 V, Sec. FLA = 867 A From manufacturer
4 Primary Voltage Branch Circuit Conductors: PEC Art. 4.30.11.4
1.25 x 450 = 562.5 Amps; PEC Art. 4.30.11.4
Sec Branch Circuit Conductors: 1.15 x 867= 997 Amps; PEC Art. 4.30.11.6
5 Wire Size at 562.5 A: USE: 1C per phase 250 mm2 XLPE PEC Table 3.10.1.67 Shielded Solid
Type MV-105, Ampacity: 640 Amps. Dielectric Cable
Wire Size at 997 A: USE 2-250 mm2 per phase. Type MV- PEC 3.10.1.60(c)(1)
105, Ampacity 1,280 A. Derated Ampacity: 1,024 A Derating Factor for 9c’s = 80%
6 Motor Controller: MV Liquid Resistor Starting Manufacturer’s Catalog FUJI Electric
7 Branch Circuit Breaker: 200% x 450 = 900 A PEC Art. 4.30.11.5 (c ) (1)a
Size of Vac Circuit Breaker: 1,250 A at 7.2 KV, See manufacturer’s Catalog to suit short
Branch Circuit Breaker: Secondary Current = 867 A. circuit rating with fault duty.
Nearest Available Vac Circuit Breaker is 1250 A at 7.2 KV,
KAIC Rating is established in separate calculations.
8 Motor-running protection: 100% to115% of motor FLA PEC 4.30.11.6 (Mandatory)

End of Chapter 5.0:

BRANCH CIRCUIT DESIGN COMPUTATIONS

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