03.01.

04 0 Issued for approval GH HVB

DATE REV. NO. DESCRIPTION CHECKED APPROVED
REVISIONS
TOTAL NO. OF PAGES- 8
LARSEN & TOUBRO LIMITED NAME SIGN DATE
ECC Division DSGN AKR 02.01.04
CHKD GH 03.01.04
APPD HVB 03.01.04
REV.
DOC. No. O 3 0 5 0 - E - C P - E E - D C - 0 0 0 5
0

RELEASED FOR PRELIMINARY TENDER INFORMATION APPROVAL CONSTRUCTION

Scale: Country: Site:

BANGLADESH CHHATAK - NOARAI
28
Size: Project :

A4 SURMA CEMENT PLANT

Title:

TYPICAL MV CABLE SIZING CALCULATION

Contract No: SUR500-2

This drawing and the information contained

herein are the property of LARSEN &
TOUBRO LIMITED.This shall not be
SURMA CEMENT
disclosed reproduced or used in any manner
without the prior written consent of LARSEN
& TOUBRO LIMITED. Document / Drawing No. Rev.
SUR.820.U44 0
 LARSEN & TOUBRO LIMITED
ECC Division – EDRC

DOCUMENT NO. DATE

PROJECT SURMA CEMENT PLANT
SUR.820.U44 02.01.04
DESIGNED CHECKED PAGE
TITLE TYPICAL MV CABLE SIZING CALCULATION
AKR GH 2 of 8 -

TYPICAL MV CABLE SIZING CALCULATION FROM MAIN MV BOARD (MV-02) TO CEMENT

MILL # 1 BOARD (MV-14.1)
Input

Cable From : Main MV Switchboard (MV-02)

Cable To : Cement mill MV Board (MV - 14.1)
Connected Load on MV-14.1 : 6709 kVA
MD on MV-14.1 : 6446 kVA
Rated Voltage : 6.6 kV
Total route length (L) : 0.18 km
System Neutral Earthing : Resistance earthed
Rated pf cosQ1 : 0.82
Type of cable selected : 6.6kV (UE), Al., Armoured, XLPE
Full load current of the feeder (If) : (6446/(Sqrt(3)*6.6))
563.9 Amps
Sizing Criteria

Cable selected should be

- Thermally strong to withstand the full load current
- Mechanically strong to withstand shortcircuit forces
- Electrically stable to limit voltage drop within spec. requirement

(i) Sizing the cable for thermal ampacity

Conditions of laying : Laid on trays (In Air)

Rating factor adopted (F) : 0.7

Size of cable selected : 3Cx300 Sq.mm.

Continuous rating of the cable (Ic) : 450 Amps (Ref: Table-IX- Unistar)
Short circuit rating of 1 run of the cable : 28.3 kA (Ref: Table-IX- Unistar)
considered

Derated capacity of the cable (I) = Ic x F

= 315 Amps

No. of runs required = If / I

= 1.79
No. of runs selected = 2.00
 LARSEN & TOUBRO LIMITED
ECC Division – EDRC

DOCUMENT NO. DATE

PROJECT SURMA CEMENT PLANT
SUR.820.U44 02.01.04
DESIGNED CHECKED PAGE
TITLE TYPICAL MV CABLE SIZING CALCULATION
AKR GH 3 of 8 -

(ii) Check for Short circuit withstand level of the cable

Actual source fault level : 31.5 kA

Source reactance (Xso) converted to
system voltage = kV2/MVAsc
= (6.6^2)/(sqrt(3)*6.6*31.5)
= 0.121 ohm
Resistance of the cable = 0.13 ohm / km (Ref: Table-IX- Unistar)
Reactance of the cable = 0.087 ohm / km (Ref: Table-IX- Unistar)
Net Resistance of the cable (R) = ((0.13*0.18)/2)
0.012 ohm
Net Reactance of the cable (X) = ((0.0866*0.18)/2)
0.008 ohm
Fault level at the load end of the cable = 6.6/(sqrt(3)*(R+j(Xso+X)))
= 29.5 kA
Cable short circuit withstand time = 0.5 sec

Short circuit withstand capacity of 2

run of cable (3Cx300 Al.) = 56.6 kA for 1 sec.
= 80.04 kA for 0.5 sec.

Hence cable selected is adequate

(iii) Check for steady state voltage drop in the cable

The values of R & X are respectively the net resistance and reactance of the cables.

Steady state voltage drop = If[RcosQ1+XSinQ1]

= 7.925 Volts

% Voltage drop = 7.93 /(6.6*1000/sqrt(3))

0.21

The voltage drop allowable as per specification is 5% and hence within limits

Hence, the cable selected 2 Runs 3C x 300SQmm shall safely withstand the effects of short
circuit and shall carry the FLC within the permitted temperature limits and voltage drops.
 LARSEN & TOUBRO LIMITED
ECC Division – EDRC

DOCUMENT NO. DATE

PROJECT SURMA CEMENT PLANT
SUR.820.U44 02.01.04
DESIGNED CHECKED PAGE
TITLE TYPICAL MV CABLE SIZING CALCULATION
AKR GH 4 of 8 -

TYPICAL HV CABLE SIZING CALCULATION FROM CM # 1 MV BOARD (14.1) TO CEMEMT

MILL MOTOR # 1
Input

Cable From : CM # 1 MV Switchboard (MV-14.1)

Cable To : Cement mill motor # 1 (416DR01MT10)
Motor capacity : 4635 kVA 3800 kW at 0.82 pf
Rated Voltage : 6.6 kV
Total route length (L) : 0.125 km
System Neutral Earthing : Resistance earthed
Rated pf cosQ1 : 0.82
Type of cable selected : 6.6kV (UE), Al., Armoured, XLPE
Full load current of the feeder (If) : (4635/(Sqrt(3)*6.6))
405.5 Amps
Sizing Criteria

Cable selected should be

- Thermally strong to withstand the full load current
- Mechanically strong to withstand shortcircuit forces
- Electrically stable to limit voltage drop within spec. requirement

(i) Sizing the cable for thermal ampacity

Conditions of laying : Laid on trays (In Air)

Rating factor adopted (F) : 0.7

Size of cable selected : 3Cx300 Sq.mm.

Continuous rating of the cable (Ic) : 450 Amps (Ref: Table-IX- Unistar)
Short circuit rating of 1 run of the cable : 28.3 kA (Ref: Table-IX- Unistar)
considered
Derated capacity of the cable (I) = Ic x F
= 315 Amps

No. of runs required = If / I

= 1.29
No. of runs selected = 2.00
 LARSEN & TOUBRO LIMITED
ECC Division – EDRC

DOCUMENT NO. DATE

PROJECT SURMA CEMENT PLANT
SUR.820.U44 02.01.04
DESIGNED CHECKED PAGE
TITLE TYPICAL MV CABLE SIZING CALCULATION
AKR GH 5 of 8 -

(ii) Check for Short circuit withstand level of the cable

Actual source fault level 25 kA

Source reactance (Xso) converted to
system voltage = kV2/MVAsc
= (6.6^2)/(sqrt(3)*6.6*25)
= 0.152 ohm
Resistance of the cable 0.13 ohm / km (Ref: Table-IX- Unistar)
Reactance of the cable = 0.087 ohm / km (Ref: Table-IX- Unistar)
Net Resistance of the cable (R) = ((0.13*0.125)/2)
0.008 ohm
Net Reactance of the cable (X) = ((0.0866*0.125)/2)
0.005 ohm
Fault level at the load end of the cable = 6.6/(sqrt(3)*(R+j(Xso+X)))
= 24.1 kA
Cable short circuit withstand time = 0.5 sec

Short circuit withstand capacity for the

cable considered = 56.6 kA for 1 sec.
= 80.04 kA for 0.5 sec.

Hence cable selected is adequate

(iii) Check for steady state voltage drop in the cable

The values of R & X are respectively the net resistance and reactance of the cables.

Steady state voltage drop = If[RcosQ1+XSinQ1]

= 3.957 Volts

% Voltage drop across MV-14-1 & Cement = 3.96 /(6.6*1000/sqrt(3))

mill motor#1 0.11
% Voltage drop across MV-02 & MV-14.1 = 0.21

Total voltage drop between Main MV-02 to = 0.32

Cement mill motor # 1 terminal
The voltage drop allowable as per specification is 5% and hence within limits

Hence, the cable selected 2 Runs 3C x 300sqmm shall safely withstand the effects of short
circuit and shall carry the FLC within the permitted temperature limits and voltage drops.
 LARSEN & TOUBRO LIMITED
ECC Division – EDRC

DOCUMENT NO. DATE

PROJECT SURMA CEMENT PLANT
SUR.820.U44 02.01.04
DESIGNED CHECKED PAGE
TITLE TYPICAL MV CABLE SIZING CALCULATION
AKR GH 6 of 8

MV LOADS AND INDICATIVE CABLE SIZES FOR MAJOR EQUIPMENTS

ROUTE LENGTH
VOLTAGE IN kV

MAX. DEMAND

TOTAL NO. OF
LOAD IN KVA
CONNECTED

CABLE SIZE

Remarks
(Mtrs.)

RUNS
(KVA)
SN
FROM TO

A Main MV Board ( MV-02 )

1 Power Plant Incomer -1 Main MV Board (MV02) 6.60 42795 41253 100 15 1C x 1000 See Note: 3
2 Power Plant Incomer -2 Main MV Board (MV02) 6.60 42795 41253 100 15 1C x 1000 See Note: 3

1 Main MV Board Raw Mill MV Board ( MV-11 ) 6.60 10489 9474 730 3 3C x 300
2 Main MV Board Kiln MV Board ( MV-12 ) 6.60 3519 3519 720 1 3C x 300
3 Main MV Board Clinker & Cooler -1 MV Board ( MV-13 ) 6.60 3309 3309 590 1 3C x 300
4 Main MV Board Cement Mill - 1 MV Board ( MV-14.1 ) 6.60 6709 6446 180 2 3C x 300
5 Main MV Board Distribution Transformer CCR& WS( 821TF05 ) 6.60 1600 1600 40 1 3C x 240
6 Main MV Board Emergency Transformer ( 828GN01TF10 ) 6.60 1250 1250 30 1 3C x 240

7 Main MV Board Lighting Tansformer ( 821TF15 ) 6.60 630 630 35 1 3C x 240

8 Main MV Board Limestone & Shale MV Board ( MV-04 ) 6.60 4350 4350 1215 2 3C x 300
9 Main MV Board Cement Mill - 2 MV Board ( MV- 14.2 ) 6.60 6709 6446 180 2 3C x 300
10 Main MV Board Distribution TransformerAdditive substation ( 403TF05 ) 6.60 1600 1600 250 1 3C x 240
11 Main MV Board Distribution TransformerPacking substation ( 500TF05 ) 6.60 2000 2000 435 1 3C x 240
12 Main MV Board Distribution TransformerCooler substation ( 900TF05 ) 6.60 630 630 610 1 3C x 240
B Limestone & Shale substation ( MV-04 )
1 Limestone & Shale MV Board Lighting Tansformer ( 822TF15 ) 6.60 250 250 35 1 3C x 240
2 Limestone & Shale MV Board Distribution Transformer ( 822TF05 ) 6.60 1600 1600 55 1 3C x 240
C Raw Mill substation ( MV-11 )
1 Raw Mill MV Board Drive transformer - ESP FAN ( 314FA01TF10) 6.60 563 563 55 1 3C x 240
2 Raw Mill MV Board Drive transformer - Raw Mill Fan ( 216FA05TF10) 6.60 3158 2679 50 1 3C x 300
3 Secondary - 1 of Drive transformer - Raw Mill Fan Raw Mill Fan VSD ( 216FA05VS10 ) 4.16 3158 2679 80 2 3C x 240
4 Secondary - 2 of Drive transformer - Raw Mill Fan Raw Mill Fan VSD ( 216FA05VS10 ) 4.16 3158 2679 80 2 3C x 240
5 Rawmill Fan VSD ( 216FA05VS10 ) Raw Mill Fan Motor ( 216FA05MT10) 4.16 3158 2679 135 2 3C x 240
6 Raw Mill MV Board Raw Mill motor ( 216DR01MT10 ) 6.60 4268 4268 110 2 3C x 300
7 Raw Mill MV Board Distribution Transformer ( 210TF05 ) 6.60 2500 2500 65 1 3C x 240
D Kiln substation ( MV-12 )
1 Kiln MV Board Drive transformer - Kiln ( 316DR01TF10) 6.60 625 625 60 1 3C x 240
2 Kiln MV Board Drive transformer - Smoke Gas fan ( 313FA01TF10) 6.60 1947 1644 75 1 3C x 300
3 Secondary - 1 of Drive transformer - Smoke Gas fan Smoke Gas Fan VSD ( 313FA01VS10 ) 4.16 1947 1644 55 1 3C x 300
4 Secondary - 2 of Drive transformer - Smoke Gas fan Smoke Gas Fan VSD ( 313FA01VS10 ) 4.16 1947 1644 55 1 3C x 300
5 Smoke Gas Fan VSD ( 313FA01VS10 ) Smoke Gas Fan ( 313FA01MT10 ) 4.16 1947 1644 65 1 3C x 300
6 Kiln MV Board Distribution Transformer ( 311TF05 ) 6.60 1250 1250 40 1 3C x 240
E Cooler ESP substation ( MV-13 )
1 Clinker & Cooler -1 MV Board ( MV13 ) Drive transformer- Cooler ESP Fan ( 318FA01TF10 ) 6.60 375 375 30 1 3C x 240
2 Clinker & Cooler -1 MV Board ( MV13 ) Drive transformer- Cooler Fans ( 317TF15 ) 6.60 934 934 25 1 3C x 240
3 Clinker & Cooler -1 MV Board ( MV13 ) Distribution Transformer ( 310TF05 ) 6.60 2000 2000 40 1 3C x 240
F Cement Mill substation # 1
1 Cement Mill - 1substation ( MV-14.1) Drive transformer- Cement Mill Filter Fan ( 416FA04TF10 ) 6.60 475 475 45 1 3C x 240
2 Cement Mill - 1substation ( MV-14.1) Cement Mill motor - 1( 416DR01MT10 ) 6.60 4635 4635 125 2 3C x 300
3 Cement Mill - 1substation ( MV-14.1) Distribution Transformer ( 410TF05 ) 6.60 1600 1600 50 1 3C x 240
G Cement Mill substation # 2
1 Cement Mill - 2substation ( MV-14.2) Drive transformer- Cement Mill Filter Fan ( 426FA04TF10 ) 6.60 475 475 45 1 3C x 240
2 Cement Mill - 2substation ( MV-14.2) Cement Mill motor - 2( 426DR01MT10 ) 6.60 4635 4635 125 2 3C x 300
3 Cement Mill - 2substation ( MV-14.2) Distribution Transformer ( 420TF05 ) 6.60 1600 1600 50 1 3C x 240
Note :
1. The cable sizes and number of runs are subjected to revision in line with the change in Load & distance.
2. This table covers main equipment cables only. Cables for LRS, MV reactor, LV capacitor etc., shall be covered in detailed MV cable schedule.
3. The cable is sized for breaker rating (3150A) and not for the maximum demand/connected load.