ELECTRICAL DESIGN

AND PROTECTION

SEMESTER 2, 2015

LECTURE 3
CABLE SIZING
 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

Building and Site Reticulation

Supply to buildings is obtained from a Network operator.

The electrical supply to the main switchboard of an installation is referred to as the "mains".
Within an installation the supplies to distribution boards is by way of “submains " and the
wiring from the distribution boards to socket outlets and lighting is by way of “final sub-
circuits”.

Types of Supply

Individual Network operators have their own methods of providing supply, however the
following are typical :-

Domestic
These are normally single phase 230 volt 60 amps with 2 phase supplies available for large
heating loads or spa pools etc. For larger installations which have greater needs 3 phase
supplies are often provided. These can be supplied overhead (o/h) or underground (u/g).

Light Commercial and Industrial

These are up to 1OOKVA- i.e. 150 A per phase (P = 3 IL VL) they could be 1 phase (e.g. small
shop), but are usually 3 phase at 400volt using either o/h or U/g.

Medium Commercial and Industrial

These are up to 2 MVA, approximately 2880 amps) e.g. factories, engineering shops, high
rise buildings, etc. Power Companies provide a supply at high voltage (usually 11 kV) to a
transformer, from which the 400V, 3 phase supply is obtained.

Heavy Industrial
These are large industrial sites with separate buildings, or well distributed load centres may
take their supply at high voltage. Metering is carried out on the high voltage supply, and the
consumer distributes around site at 11 kV.

The distribution around the site or installation (reticulation) can be achieved by different
methods.

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

Types of Reticulation

:
Radial for proj
This is by far the most common method.

Advantages of this system are :

Provides a simple basis for load assessment.

-

easy operation
Provides a straight forward -

The protection requirements can be clearly defined (no parallel

feeds).
Requires a minimum of switching devices.

The disadvantages are :-

A fault on a submain disconnects all subcircuits fed by it.

Only one path is available for supply which does not allow load sharing.
Losses and volt drops are high.

Ring Mains Expensive

This type of system is not common in New
Zealand installations, however it finds
applications in large installations where
continuity of supply is critical i.e. Auckland
Hospital. Power Companies commonly use
ring main distribution for their high voltage
supply systems.

Using section isolators or ring main units

(RMUs) any faults which occur in the
distribution system can be isolated without
loss of supply to the distribution boards.

Advantages of this system are :-

Continuity of supply is assured.

Being fed from both ends, load sharing between cables occurs.
Losses and volt drops are reduced.
The ring cable size can be reduced to 0.7 the rating of the main circuit breaker.

The disadvantages are :-

Increased cost due to extra switch gear and cable.

Discrimination of protection is reduced.

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

Rising Main Distribution More Common

This is the method commonly used in multi-story buildings.

It consists of a vertical system of conductors, with distribution

boards installed on the various floors of the building.

The conductor system may consist of cables or a vertical bus bar

system.

Whichever system is used, a supply which may be > 1000 amps is

obtained at the main switch board and as this rises through the
building, fused tap offs are used to connect the distribution boards.

If the load reduces substantially, the size of the conductors can be

reduced. When this is done protection must be provided for the
reduced section.

In the case of the bus bar system, as well as being designed to cope
with the short circuit stresses likely under fault conditions, provision is required to:-

Support the vertical weight of the conductors.

Provide for expansion and contraction (flexible joints).
Prevent spread of fire and smoke between floors.
Prevent heat dissipated from the system rising to the top sections of the duct.

Advantages of the rising main system are :-

They can provide a cost saving, against using individual cables to supply each floor.
They reduce the size of the main switchboard.
They provide a system which allows for additions to the installation, provided
sufficient capacity is provided in the original installation.

Disadvantages :-

Lack of individual protection.

Loading of additional equipment is limited by the rising mains capacity.

÷¥F 4
 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

Typical Cable Types

Insulation of cables

For use on the standard 230volt, lph, and 400volt 3 ph 4 wire systems the insulation rating
required is 600/1000V.

For PVC insulation a maximum conductor temperature of 60 oC ( standard PVC ), 75oC ( heat
resistant PVC ) must be observed. 90oC for XLPE.

PVC Conduit wire ( PVC = Polyvinyl Chloride Compound ) Control

With copper conductors. This type of cable has no mechanical protection and requires to be
installed within a medium, such as metallic or plastic conduit or trunking systems. With
suitable protection conduit wire is extensively used for lighting, power, and motor circuits
etc. in industrial and commercial installations.

wiring
Available in sizes ranging from 0.5 mm2 to 630mm2

A full range of colours are also available.

TPS cables. ( Tough plastic sheathed )

With copper conductors. Used extensively for domestic and light industrial and commercial
installations. Can be installed without protection within stud walls and ceilings and can be
clipped to surfaces. Where surface installation is required below 2 metres or where
mechanical damage may occur protection such as ducting, casing, conduit etc. is required.
This type of cable is not generally used in heavy industry because of the difficulty of
installation and lack of protection.

skinned :*
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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

Available in sizes from 1.00 mm2 to 16 mm2, 2 core, 2 core + E, 3 core, 3 core + earth, 4 core..
The outer sheath is normally white put can be found in red (for fire alarms circuits ) or other
colours to order.

1.5mm2 cabling is generally used with a 16A. (or sometimes 10A,) MCB protection device for
lighting subcircuits.

2.5mm2 cabling is generally used with a 20A. MCB protection device for small power
subcircuits.

Neutral screened cable. ( PVC insulated with copper conductors ) Street lighting

In the soft drawn form this type of cable is used extensively for mains and sub mains within
buildings. The hard drawn form is suitable for aerial lines. The screen can be used either as
the neutral or earth continuity conductor.
circuit
we .

Sizes include 6mm2 to 25mm2 for the single a two core types going up to 50 mm2 for the
three core.

Note! The cables above all have copper conductors in the smaller sizes. This is because of
the difficulty in terminating aluminium conductors. In larger sizes aluminium offers
economic advantages in some cases, and there are special jointing techniques available. (Bi-
metal lugs. barrier compounds etc.)

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

PVC Insulated mains cables. cable

Sub main .

70°C .

These may be armoured or unarmoured. When armoured, this consists of a layer of

galvanized steel wires contained within the outer PVC sheath. In this form the cables can be
installed without further protection. The unarmoured form requires protection when
installed below 2metres or where mechanical damage could occur. If single core armoured
cables are required the armouring wire must be non magnetic, i.e. aluminium.

insulator
y

Available in sizes 1.5 mm2 to 300 mm2

This type of cable is used for mains and submains in commercial and industrial installations,
as well as for supplying equipment with substantial electrical loading. The conductors may
be copper or aluminium and in the case of aluminium the conductor may be solid or
stranded.

1×4650 mm 'CU PVYPK the

€@@

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

Cross linked polyethylene insulated mains cable ( XLPE ).

This form of insulation is a thermoset, rather than thermoplastic material, and can stand

a
higher conductor temperatures ( up to 90oC ). This can allow higher current carrying
capacity, subject always to voltage drop considerations.
µ .
-
current .

Sizes are from 2.5 mm2 to 300 mm2

As for PVC mains cables XLPE cables can have copper or aluminium conductors, and may be
armoured or unarmoured. The XLPE is for the conductors with the outer sheath being PVC.

It also has better insulating properties than PVC that allow the cable to achieve voltage
rating with thinner insulation coatings.

Note! The choice of cables for mains and submains must take into account the type of
installation (i.e. surface, on-tray or rack.. drawn through pipes or ducts etc), which will
provide physical restrictions.

The length of run often determines whether PVC or XLPE will be most economic for a given
loading, and also dictates the choice between aluminium and copper conductors.

Aluminium conductors for a given loading will be approximately 30% larger in diameter but
will be lighter in weight. Aluminium cables are usually more difficult to install and terminate,
however in some circumstances the lower cost of aluminium can offer economic
advantages, and its use should be considered.

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

Paper insulated mains cables.

Prior to the availability of PVC and XLPE this type of cable was used extensively for heavy
industry use. Became limited to uses at voltages of 11kV plus.

Typical Designations are :-

PILCSTA Paper insulated - Lead covered - Steel tape armoured

PILCSWA As above with steel wire armoured ( greater longitudinal

strength for hauling in)

The lead sheath is to exclude moisture, which will break down the insulating quality of the
paper. Special jointing techniques are required to seal the ends.

Mineral insulated metal sheath (Pyrotenex).

This cable consists of copper or aluminium conductors contained inside a metallic sheath of
the same material. The insulation is compressed powdered mineral ( normally magnesium
oxide), which is fire proof. The complete cable may have an outer sheath of PVC, to protect
against corrosion. High current ratings for short runs make MIMS suitable for mains cables,
and its high temperature properties (up to 900oC) make it suitable where the need for
superior fire retardant properties are important, i.e. submains to life support equipment
such as fire pumps, lifts, etc., or where RFI emission may be a problem.

Very robust cable, the problem lies in the terminations where, should moisture ingrate into
the inner core, the mineral salt insulation becomes useless. This can only be elevated by
careful application of heat to ‘drive’ the moisture out. A recent innovation of ‘speed tape’
has reduced the risk of this and vastly reduced the cost of finishing of the cable connection.

MIMS cables do not burn or melt and will operate under fire conditions, but are difficult to
install and require skilled labour to fit off.

MIMS cables require the use of surge diverters, where the risk of high transient voltages
exist ( lightning strikes).

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

Butyl rubber

Resistant to ozone and weathering and suitable for temperatures up to 85deg.C. Commonly
used in marine applications, and has been used for large single core mains cables.

Silicon rubber

Suitable for temperatures up to 150deg.C and is often used for insulation on flexible cables.

Fire Retardant Cables / Special Cables

Although PVC has some inherent flame retardant properties there are more specialised fire
retardant, low smoke and zero halogen type cables available. These are known under their
brand names ie. Radox or Pyrolex.

There are many other cables available which are resistant to a wide range of chemicals etc.

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LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

Cable support systems

Cables may be fixed directly to surfaces by methods such as clipping to timber , and saddling
onto steel and concrete etc. As well, a large number of proprietary systems are available to
support or enclose cables. Some of the most common are described.

For larger mains and power cables, systems of racking and cable trays are available. These
are erected on supports fixed to walls, steelwork, and in ducts etc, and are used for running
groups of power and control cables, usually of the type requiring little or no mechanical
protection. (MIMS, PVCSWAPVC, etc.)

Conduit (PVC or steel)

Can be steel or PVC, steel for the heavier duty and harsher environments typically found in
heavy industry.
Plant room
Exposed ceiling

Ducting and trunking.

These enclosures are used for single or double insulated cables and can be installed on the
surface or concealed under floors.

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

Trunking systems would be found in large city buildings, factories and commercial
installations.

Advantages include :-

Ease of access to install new cables.

Easily adapted to other systems.

Disadvantages include :-

Initial high cost

Cables may need de-rating because of bunching
Any faults in an enclosure may affect other cables / circuits.

Busbar trunking

Busbar trunking is used for rising mains in high rise buildings. It also finds used installed
overhead in retail areas where tap offs provide a feed to feed individual shops and in
datacentres where tap offs provide a feed to data racks.

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

( aeenary :
Areas with few And sub .
circuit cable Ma×= 57ps .

Protective channelling or capping

Protective channelling or capping is used to provide extra protection to cables which have
been run on the surface. Extra protection may be required when surface run cable come
below 2 metres of the floor and are subject to possible damage.

Cable tray Major Run .

Cable tray is a “light duty” support used where there is a number of “smaller size” cables
being run. Often found in the ceiling space of office blocks or in risers, switch rooms,
basements, boiler houses, and other places not normally occupied by people.

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

Cable rack (Ladder rack) hold more weight .

Cable ladder is generally used for heavy duty industrial applications and large sub-main
cables.

Catenary Wire

Catenary wire is generally used for final sub-circuits where there are few cables being run in
an area. The max that should be supported on a catenary is 5 TPS cables to prevent excess
weight and heat build-up.

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

Cable Installation

The way the cable is installed is influenced by a number of factors. These are likely to be;

The proximity of other cables and how this will influence the subject cable.
The ambient temperature.
The amount of current the cable needs to carry.
The amount of volt drop allowed on the cable run.
Physical space constraints.

Unenclosed Cables

Cables deemed ‘unenclosed’ are installed under the following conditions.

Directly in air (assumed at 30OC for New Zealand ambient conditions else
adjustments need to be made).
Lying on a horizontal surface, across ceiling joists, etc.
Supported on cable tray, ladder, hangers or racks.
Clipped at spaced intervals on vertical or horizontal surfaces.
Suspended from catenary wire.
Lying in the bottom of open trunking
Enclosed in switchboards.
Directly embedded beneath the surface of plaster, cement render or masonry.

Enclosed Cables

Cables deemed ‘enclosed’ are installed under the following conditions.

In a metallic or non-metallic enclosure run in;

o free air
o a ventilated or enclosed trench
o concrete slab or above the surface of the ground.
o A concrete, plaster, cement rendered or masonry wall.
In closed trunking
In an enclosed trench with removable covers.
Directly buried in concrete.

Definition of run

Where the cable run crosses different types of installation criteria, then some choice needs
to be made on how to rate the cable to the installation conditions.

AS/NZS 3008 offers the following advice:

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

Where (otherwise) unenclosed cable includes short lengths of wiring enclosure which do not
restrict free circulation of air, the current carrying capacity of the cable may be as
‘unenclosed’ providing;

The above ground run does not exceed half the cable length or 6m (whatever is the
shorter).
The wiring is not surrounded by thermal insulation.
The wiring enclosure is of adequate dimension to allow for heat dissipation.

A conservative ‘rule of thumb’ is that if more than 1 metre of cable exceeds the
configuration enjoyed by the majority of the cable run length, then use the lower ratings
listed.

Thermal Insulation

Be aware that when cables are run in, or under thermal insulation, stricter cable ratings
apply.

Underground Cables

Cables run underground can be buried direct or enclosed in conduit. The choice depends on
the ground conditions, mechanical protection required and soil content.

It is assumed that the ground ambient temperature is 15o C and the cables are laid at a
nominal depth of 500mm below the surface, with a soil thermal resistivity of 1.2o C.m/W.
Where any of these three factors vary, then the cable rating need to be adjusted to suit.

Influence of Other Cables

The current carrying capacity of a cable is affected by the presence of other cables. Where
these ‘groups’ influence each other, the cables need to be derated to suit or the cables need
to be spaced apart to avoid the need for derating.

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

AS/NZS 3008 – Typical Cable Table Discussion

The following table is typical of that within the Standard that details the current ratings for
copper and aluminium cables, run in different configurations.

Taking a 25mm2 Cu. Cable run for three phases:

CONFIGURATION CURRENT VOLT DROP

RATING (A) (mV/A.m)

Spaced, flat 137

Spaced from the surface, trefoil 120

Touching 111

PVC Conduit, air 99

PVC conduit, partially surrounded, thermal 82

insulation

Unenclosed, partially surrounded, thermal 82

insulation 1.62

PVC conduit, fully surrounded, thermal 55

insulation

Unenclosed, fully surrounded, thermal 55

insulation

Buried direct 149

Buried, PVC conduit, same duct 116

Buried, PVC conduit, individual ducts 132

Compare this with the ratings for 25mm2 single core cables with that of a composite 3 core
25mm2 cable.

CONFIGURATION CURRENT VOLT DROP

RATING (A) (mV/A.m)

Single core, flat 137 1.62

Single core, trefoil 137 1.62

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
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CONFIGURATION CURRENT VOLT DROP

RATING (A) (mV/A.m)

Composite cable 132 1.61

Compare this with the ratings for 150mm2 single core cables with that of a composite 3 core
150mm2 cable.

CONFIGURATION CURRENT VOLT DROP

RATING (A) (mV/A.m)

Single core, flat 376 0.330

Single core, trefoil 376 0.316

Composite cable 348 0.307

It can be seen that the installation configuration doesn’t influence the volt drop
characteristics of the cables for the smaller cable sizes as it does for the larger ones. This is
because, as the cable size increases, the reactance of the cable plays a greater part in the
interaction than it does in the smaller sizes.

The installation influences the current carrying capacity of the cable, whatever the size or
type of construction (single core, composite, unscreened, screened, etc.).

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
AND PROTECTION

Cable cross sectional area ( CSA ) selection

Once a “type“ of cable and an installation method has been decided upon the conductor
cross sectional area needs to be determined.

The two key factors to be considered are :-

Current drawn by the circuit

P = 3 VL IL Cos ( 3 phase circuits ) P = VL IL Cos ( 1 phase circuits )

NZS 3008 gives the maximum values of current that a given conductor can carry
continuously without the insulation being damaged by the build up of heat. The heat is
developed by virtue of the current passing through the cables resistance resulting in I2R
losses (heat).

General purpose PVC can withstand a conductor temperature of 75oC without insulation
damage occuring. (90oC for XLPE insulation)

The ability of cables to dissipate the heat built up depends alot on how it is installed. If the
cable is installed within an insulating material e.g. ceiling insulation, the heat will not be
dissipated as it would have if it was installed in open air. The same current will then cause
excessive heat build up in this case, the current rating for a cable installed in thermal
insulation is lower than the same cable installed in air.

The environment in which the cable is installed (ambient temp included) then has an effect
on the cable current carrying capacity.

Voltage drop

Because all cables have some resistance a voltage drop will occur when current is passed
through it. If the voltage drop is excessive poor operation of equipment will result.

The Wiring Rules give 5% as being the maximum voltage drop permissable from the point of
supply if the transformer is off site and 7% if the transformer is on-site..

The point of supply is defined as the point at which the supply crosses the boundary of the
property, not the switchboard.

It is common to use 2.5% from the distribution board to the end if the final sub-circuit
cables. The rest is made up depending on the length of the runs up stream.

Because electric motors have a minimum start voltage (can be around 350V) voltage drop
needs to be considered using a motors start up current.

Voltage drop and current ratings can be determined from the tables within AS/NZS 3008.

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
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Example 1

A 3 phase, four wire PVC insulated SWA multicore cable 50 metres long is to be used for a
submain. The cable will be installed direct to the surface in an area where the ambient
temperature will not exceed 35oC. The maximum power is 25 kW @ 0.8 pf. Find the
minimum cross sectional area of the cable.

Example 2

A 75 kW, 3ph, 400v motor has an efficiency of 85% and a full load power factor of 0.8. It is to
be wired using XLPE single core cables installed in conduit. The length of run is 30 metres
and the area through which the canle runs has an ambient temperature of 35oC.

Select the most suitable cable size.

Example 3

A 100 kW, 3 ph, 400v motor has an efficiency of 82% and a full load power factor of 0.78.
The cable is to be PVC multicore, it will be clipped direct on a cable tray and the length of run
will be 20 metres. The ambient temperature will not exceed 30oC. When started direct on
line the motor will draw 5 times its full load current. The min starting voltage for the motor
is 380 v.

Determine the most suitable cable size.

De-rating Factors

The above examples are valid only if the installation conditions are standard.

Further de rating may be required because of :-

Direct sunlight
Grouping of cables
None standard soil thermal resistivity

Short circuit temperature rating of cables

It was previously mentioned that standard PVC can withstand a continuous conductor
temperature of 70oC, 90oC for XLPE, without damage. This continous temperature limit can
be exceeded for a short period only during short circuit faults.

The short circuit ( short time ) temperature rating for PVC is 160oC, with 250oC for XLPE.

For a given short circuit current the time it takes for this limit to be reached depends upon :-

Conductor csa
K factor for the insulation type ( this will always be given ).

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 LECTURE 3 – Cable Sizing ELECTRICAL DESIGN
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The adiabatic formulae is used.

I2t = K2S2

Where :-

I = Short circuit current

t = Time it will take to reach temperature limit in seconds

K = Constant for cable type

S = Cable csa in mm2

Example 1

Determine the time it would take for the temperature of a 50mm2 PVC insulated cable to
rise to the short circuit temperature limit if a fault of 5 kA is sustained. K for the cable is 122.

Eample 2

A circuit is protected by an Air Circuit breaker rated at 10 kA with a clearance time of 1

second. Determine the min cable size based on the short circuit temperature rise for :-

A PVC insulated cable with a K of 111

An XLPE cable with a K of 143.

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