ELEC 423

Distribution of Power System

Power Distribution Cables

Adel Gastli

Adel Gastli
 CONTENTS

1 •Types of Power Distribution Cables

2 •Cable Selection Criteria

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Adel Gastli
3 •Short Circuit Current Calculation

4 •Cable Risers and Trays

Prof. Adel Gastli ELEC432: Electric Power Distribution Systems 2

 CONTENTS

1 •Types of Power Distribution Cables

2 •Cable Selection Criteria

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3 •Short Circuit Current Calculation

4 •Cable Risers and Trays

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 TYPES OF POWER CABLES
 Power cables are usually classified LV
according to their operating voltage as
follows:
1. Low voltage cables (up to 1kV)
2. Medium voltage cables (3kV up to 30kV). MV
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3. High voltage cables (66kV up to 500kV).

For same cross sectional area, single core

cables Ampacity is greater than that of HV
multicore cables. But from economics point
of view multicore cables are preferred.
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 TYPES OF POWER CABLES
 Conductors: different resistivity
Copper is used with low voltage for
minimum voltage drop (lower Cu
resistivity than Aluminum and
higher conductivity).
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Aluminum is used with medium and
high voltage for smaller current Al
ampacity and thus fewer voltage
drop.
Ampacity is defined as the maximum current, in amperes,
that a conductor can carry continuously under the
conditions of use without exceeding its temperature rating
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 TYPES OF POWER CABLES
 Insulation:
Cross Linked Polyethylene (XLPE)
cables
• Used with medium voltage and
sometimes low but is very expensive so
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its more preferable in medium.
Circular Stranded Conductor
• Cable tolerates higher current than PVC
cables.
• Withstands higher temperature, thus XLPE Insulation

current carrying capability is higher FR-PVC Sheath

Al Wire Armored
than PVC (up to 90 degrees Celsius).
Overall FR-PVC Sheath
• Higher short circuit capability than PVC.
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 TYPES OF POWER CABLES
Polyvinyl Chloride (PVC) cables:
• Popular in low voltage applications
• Lower cost than XLPE but less current capacity
• Resistant to water, oil, alkalis and doesn’t burn
easy thus requires less replacement.
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• High melting temperature. At high
temperature it turns into soft material at
higher than 80 degrees Celsius.
• Thus can be used with temperature not more
than 70 degrees.

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 CONTENTS

1 •Types of Power Distribution Cables

2 •Cable Selection Criteria

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3 •Short Circuit Current Calculation

4 •Cable Risers and Trays

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 CABLE SELECTION CRITERIA
 Beyond choosing between aluminum or copper, the
wiring expert will understand the difference between
stranded and solid wire and will choose the appropriate
wire core to use for their chosen project.
 While solid wire consists of a single metal core, a
Stranded Solid
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stranded wire is composed of numerous thinner wires
twisted together into a cohesive bunch.
 Both types of wire are appropriate for commercial and
residential installation, however each has particular
advantages and disadvantages that lead to the choice of
one over another for each particular application.

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 CABLE SELECTION CRITERIA
 While both types of wire will transmit electricity effectively,
each is better suited to specific applications in both residential
and commercial uses.
 Solid wire is the wire of choice for outdoor or rugged-duty
applications which may expose the wire to corrosive elements,
or adverse weather condition. Stranded Solid
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 Stranded wire, conversely, serves a better purpose in intricate
usages, such as electronic devices and circuit boards, where the
wire will be protected but may undergo bending or twisting in
order to connect electronic components.
 The advantages of solid wire are cost, simplicity and durability.

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 CABLE SELECTION CRITERIA
 Cables are selected based on the following characteristics:
 Cable ampacity (capacity): maximum current carried by cable, depends
on burial depth, environment, air or cable tray distribution, soil
temperature, grouping …etc. Current must be calculated using de-rating
factors.
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 Voltage drop allowance: very critical in low voltage distribution
networks.
 Short circuit withstand capabilities: Short circuit current versus time
relation. Will the selected cable withstand the expected short circuit
current at fault for the given time duration or not and will the circuit
breakers operate before the cable failure.

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 CABLE SELECTION CRITERIA
 Step 1: Cable Selection:
1. Determine the allowable current in circuit (Iz) which is proportional to
the cross section of the defined cable which includes the protective
element.
2. Determine the de-rating factors (k factor).
3. Get (Iz’) which is the Iz divided by k and this determines the cable
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ampacity.
4. Select a cable based on Iz’.
 Step 2: Perform your voltage drop calculations: either manually or using
load moment and chart techniques.
 Step 3: Short Circuit check: Make sure that your selected cable cross section
can withstand short circuit for a certain time interval until protection
responds.
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 CABLE SELECTION CRITERIA
 Derating Factors ( k-factor determination):
 Examples:
Ground temperature derating factor Air temperature derating factor
Ground PVC cables XLPE cables Air PVC cables XLPE cables
Temperature rated at rated at 90oC Temperature rated at rated at 90oC
oC oC 70oC
70oC
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25 1.13 1.09 25 1.22 1.14
30 1.07 1.04 30 1.15 1.10
35 1.00 1.00 35 1.68 1.05
40 0.93 0.95 40 1.00 1.00
45 0.85 0.90 45 0.95 0.90
50 0.76 0.85 50 0.82 0.89
55 0.65 0.83 55 0.71 0.84

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 Applied Laying Depth

CABLE SELECTION CRITERIA Type of Cable Used Depth

(cm)
LV 50-80
MV 80-100
HV 100-120
Burial depth derating factor EHV 120-140
Depth of Cable cross section (mm2)
Laying (m) Up to 70 mm2 95 up to 240 mm2 300 mm2 & above
0.50 1.00 1.00 1.00
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0.60 0.99 0.98 0.97
0.80 0.97 0.96 0.94
1.00 0.95 0.93 0.92
1.25 0.94 0.92 0.89
1.50 0.93 0.90 0.87
1.75 0.92 0.89 0.86
2.00 0.91 0.88 0.85

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 CABLE SELECTION CRITERIA

Soil thermal resistivity derating factor PVC rated temperature derating factor
Soil thermal resistivity Derating Factor Type of PVC rated Derating Factor
in oC.cm/Watt temperature (oC)
80 1.17 70 1.000
90 1.12 85 1.195
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100 1.07 95 1.309
120 1.00 105 1.414
150 0.91
200 0.80
250 0.73

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 CABLE SELECTION CRITERIA
 Voltage Drop:
Usually, voltage drop in distribution systems (LV) must not
exceed a total of 8%
• Transformer= 1%
• From distribution transformer to main distribution panel board (inside
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building)=3%
• Riser = 1-1.5%
KAHRAMAA’s Standard
• Rest = 2.5%

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 CABLE SELECTION CRITERIA
Example of SIEMEN’s
Chart with %voltage
drop (on 220/380V
supply, power factor
=0.9, and conductor
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temperature 50oC)

VD pu  KS3 leff

Load Moment

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 CONTENTS

1 •Types of Power Distribution Cables

2 •Cable Selection Criteria

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3 •Short Circuit Current Calculation

4 •Cable Risers and Trays

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 SHORT CIRCUIT CURRENT CALCULATION
 During a short circuit, a high amount of current can
flow through a cable for a short time.
 This surge in current flow causes a temperature rise
within the cable. Isc >>>
 High temperatures can trigger unwanted reactions
in the cable insulation, sheath materials and other
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components, which can prematurely degrade the
condition of the cable and may ignite fires.
 As the cross-sectional area of the cable increases, it
can dissipate higher fault currents for a given
temperature rise.
 Therefore, cables should be sized to withstand the
largest short circuit that it is expected to see during
a specific period of time.
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 SHORT CIRCUIT CURRENT CALCULATION
Symmetrical
 Short circuit could be :
Most
Symmetrical (3phase), severe
Unsymmetrical Most
• two phase, Unsymmetrical
occurred

• two phase to earth,

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2-phases
• single phase to earth)
 Most occurred ones is single 2-phases to earth 1-phase to earth
phase to earth and symmetrical
3 phase fault (most severe).
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 SHORT CIRCUIT CURRENT CALCULATION
 Minimum Cable Size Due to Short Circuit Temperature
Rise
The minimum cable size due to short circuit temperature rise is
typically calculated with an equation of the form:
2
I t
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A sc

K
Isc = Prospective short circuit current (A)
A = Minimum cross sectional area of cable conductor (mm2)
t = Duration of the short circuit (Time to trip) (seconds)
K = Cable short circuit factor (short circuit temperature rise constant)
http://www.openelectrical.org/wiki/index.php?title=Cable_Sizing_Calculation

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 SHORT CIRCUIT CURRENT CALCULATION
 The temperature rise constant K is calculated based on the material
properties of the conductor and the initial and final conductor
temperatures.
 Different international standards have different treatments of the
temperature rise constant.
 As an example, IEC 60364-5-54 calculates it as follows:
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  f  i 
K  226 ln1   (for copper conductors) i and f are the is the
 234.5   i  initial and finale conductor
  f  i  temperatures (deg C)
K  148 ln1   (for aluminium conductors) respectively.
 228   i 
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 SHORT CIRCUIT CURRENT CALCULATION
 Initial and Final Conductor Temperatures
 The initial conductor temperature is typically chosen to be the maximum
operating temperature of the cable.
 The final conductor temperature is typically chosen to be the limiting
temperature of the insulation.
 In general, the cable's insulation will determine the maximum operating
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temperature and limiting temperatures.
 As a rough guide, the following temperatures are common for the
different insulation materials:
Material Max Operating Temperature oC Limiting Temperature oC
PVC (Polyvinyl chloride) 75 160
EPR (Ethylene Propylene Rubber) 90 250
XLPE (Cross-linked polyethylene) 90 250
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 SHORT CIRCUIT CURRENT CALCULATION
 The short circuit energy (Isc2t), is normally
chosen as the maximum short circuit that the
cable could potentially experience.
 However, for circuits with current limiting
devices (such as HRC fuses), then the short- High Rupturing Capacity
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(HRC) Fuses
circuit energy chosen should be the maximum
prospective let-through energy of the
protective device, which can be found from
manufacturer data.

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 SHORT CIRCUIT CURRENT CALCULATION
Example of kA short circuit current- Copper conductor- PVC insulated
Short-circuit current limits (kA)
Duration sec.
C.S.A. mm2 0.1 0.2 0.3 0.4 0.5 1.0 2.0 3.0 4.0 5.0
16 5.8 4.1 3.4 2.9 2.6 1.8 1.3 1.1 0.9 0.8
25 9.1 6.4 5.2 4.5 4.1 2.9 2.0 1.7 1.4 1.3
35 12.7 9.0 7.3 6.4 5.7 4.0 2.8 2.3 2.0 1.8
50 18.2 12.9 10.5 9.1 8.1 5.8 4.1 3.3 2.9 2.6
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70 25.5 18.0 14.7 12.7 11.4 8.1 5.7 4.6 4.0 3.6
95 34.5 24.4 19.9 17.3 15.5 10.9 7.7 6.3 5.5 4.9
170 43.6 30.9 25.2 21.8 1.0 9.'i 1'1.8 9.R 6.9 0.2
150 54.5 38.6 31.5 27.3 24.4 17.3 12.2 10.0 8.6 7.7
185 67.3 47.6 38.8 33.6 30.1 21.3 15.0 12.3 10.6 9.5
240 87.3 61.7 50.4 43.6 39.0 27.6 19.5 15.9 13.8 12.3
300 109.1 77.1 63.0 54.5 48.8 34.5 24.4 19.9 17.3 15.4
400 130.0 91.9 75.1 65.0 58.2 41.1 29.1 23.7 20.6 18.4
500 162.5 114.9 93.8 81.3 72.7 51.4 36.3 29.7 25.7 23.0
630 204.8 144.8 118.2 102.4 91.6 64.8 45.8 37.4 32.2 29.0
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 EXAMPLE OF CABLE SELECTION
EXAMPLE

 In this example, we will size a cable

for a 415V, 37kW three-phase
motor from the MOTOR Control
Center (MCC) to the field.
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 What is the minimum size of the
cable based on short circuit
temperature rise?

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 EXAMPLE OF CABLE SELECTION
 The following data was collected for the
cable to be sized:
 Cable type: Cu/PVC/GSWB/PVC, 3C+E, 0.6/1kV
 Operating temperature: 70oC Fuse: fault I2t = 90 kA2s ,
5s melt time = 550A
 Cable installation: above ground on cable
ladder bunched together with 3 other cables on
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a single layer and at 30oC ambient temperature. 90m
 Cable run: 90m (including tails)
Cu/PVC/GSWB/PVC,
 Motor load: 37kW, 415V three phase, full load 3C+E, 0.6/1kV
current = 61A, power factor = 0.85
 Protection: aM fuse of rating = 80A, max
37kW, 415V, 61A,
prospective fault I2t = 90 kA2s , 5s melt time = cos=0.85
550A
GSWB (Galvanised Steel Wire Braid):A type of cable armouring for mechanical protection.
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 EXAMPLE OF CABLE SELECTION
SOLUTION
Step 1: Cable Selection Based on Current Rating
Derating Factors:
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Derating factor for ambient temperature of 30oC is 1.15
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 CABLE SELECTION
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Derating factor for groups of 4 multicore cables on a single
layer is: 0.79

The overall derating factor is: 1.15x0.79 = 0.9085

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 EXAMPLE OF CABLE SELECTION
Given that the rated motor current is 61A then a first choice will be the followings
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 EXAMPLE OF CABLE SELECTION

Considering the previously calculated overall derating factor then the

installed current rating of 65.4A which exceeds the motor full load current,
and is therefore the cable that should be selected based on current rating.

c.s.a mm2 Factory Current Installed Current

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Rating (A) Rating (A)
16 72 72x0.9085=65.4

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 SHORT CIRCUIT CURRENT CALCULATION
 Step 2: Cable Selection Based on Voltage Drop
 Suppose the 16 mm2 cable is selected.
 If the maximum permissible voltage drop is 5%, is the cable suitable for a run length of
90m?
 A 16 mm2 cable has an ac resistance of 1.39 Ω/km and a negligible ac reactance.
 The voltage drop across the cable is:
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 
VD  Il r cos   x sin    61 0.09  1.39  0.85  0.0  sin(cos 1 (0.85)  9.509 V
9.50
%VD  100  3.96%
415 / 3
 which is lower than the maximum permissible voltage drop of 5%.
 Therefore the cable is suitable for the motor based on voltage drop considerations.

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 SHORT CIRCUIT CURRENT CALCULATION
 Step 3: Short Circuit Temperature Rise
 The cable is operating normally at 75oC  i  75 o C and  f  160 o C
and has a prospective fault capacity (I2t)
of 90,000 A2s.
 PVC has a limiting temperature of 160oC.  160  75 
K  226 ln1  
 234.5  75 
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 Using the IEC formula, the short circuit
temperature rise constant is 75.78.  75.78
 The minimum cable size due to short
circuit temperature rise is therefore I sc2 t 90,000
3.958 mm2. A 
K 75.78
 Therefore, our 16 mm2 cable is still  3.958 mm 2
suitable for this application.
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 EXAMPLE OF CABLE SELECTION
 Moreover, if we check with the cable manufacturer catalogue, we can notice that
the selected 16 mm2 cable can withstand 800A for a duration of 5sec which is
suitable since the selected fuse will melt at 5s for less current of 550A.
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