DBR_Cable Selection and Sizing_E-TSC1-725!14!3001

2 X 600 MW SINGHITARAI THERMAL POWER PROJECT SINGHITARAI - CHHATTISGARH

Owner:

ATHENA CHHATTISGARH POWER PVT. LTD., In Front of Carmel School, Near Guru Building, Govind Garden, Laxmipur, Raigarh, Chhattisgarh - 496001

Owners Engineer:

ENERGY INFRATECH PVT.LTD. Thermal Power Divison, 7-1-24, B Block, 5th Floor, Roxana Towers, Greenlands, Begumpet, Hyderabad-500016 Ph No.:91-40-66570881, Fax No.:91-40-66570888

EPC Contractor:

ABIR Infrastructure Private Limited, Thermal Power Divison, 7-1-24, B Block, 5th Floor, Roxana Towers, Greenlands, Begumpet, Hyderabad-500016 Ph No.:91-40-66570881, Fax No.:91-40-66570888

Consultant To EPC Contractor:

TPSC(I) PRIVATE LIMITED (Wholly owned subsidiary of Toshiba Plant Systems & Services Corporation, Tokyo, Japan)

A-1 Module, D - Quadrant, 2nd Floor, Cyber Towers, Hi-Tec City, Madhapur, Hyderabad - 500 081, INDIA

Document Title: DBR FOR CABLE SELECTION AND SIZING

ABIR Document No.:

STPP-5311-E-11-03-3001, Rev-00

Consultant Doc. No.

E-TSC1-725-14-3001, Rev. 0

DBR FOR CABLE SELECTION & SIZING

Project

2 X 600 MW SINGHITARAI THERMAL POWER PROJECT

AT SINGHITARAI, CHHATTISGARH Doc. No.: E-TSC1-725-14-3001

Rev 0

Date 18-04-2011 Page 1 of 17

DOCUMENT CONTROL SHEET

0 20-04-11 First Issue AM RB DN MS

REV

NO DATE STATUS

INTLS SGN INTLS SGN INTLS SGN INTLS SGN

PREPARED BY CHECKED BY APPROVED BY ISSUE

AUTHORISATION


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CONTENTS

Sl. No Particulars Page No.

1.00.00 PURPOSE 2

2.00.00 PLANT INFORMATION 3

3.00.00 REFERENCE DOCUMENTS:- CODES & STANDARDS 4

4.00.00 CABLE SELECTION & SIZING CRITERIA 5

5.00.00 ELECTRICAL NETWORK CHARACTERSTICS 5

6.00.00 TECHNICAL REQUIREMENT OF CABLE 6

7.00.00 SIZING OF POWER CABLE 9

8.00.00 SIZING OF CONTROL CABLE 16

9.00.00 CONCLUSION 16

ANNEXURE POLYCAB CATALOGUE FOR DERATING FACTOR 1 SHEET


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1.00.00 PURPOSE

1.01.00 The aim of this document is to give the method and parameters enabling the calculation for selection and sizing of power cables taking into account the rated current, length between main distribution switchboard and electrical consumers, and the de-rating factors due to site and installation conditions and philosophy for selection of control cables for 2X600 MW Coal based Thermal Power Plant at Singhitarai in Chhattisgarh State of India.

2.00.00 PLANT INFORMATION

1 Owner : ATHENA CHHATTISGARH POWER

PVT LTD.

2 Project Name : 2X600 MW SINGHITARAI THERMAL

POWER PROJECT.

3 Location : Singhitarai, Chhattisgarh

4 Ambient Temperature :

(i) Minimum : 8 degree C

(ii) Maximum : 46.5 degree C

6 Relative Humidity : 35% Min , 88 % Max

6 Seismic Zone : Zone – III, as per 1893-2002

7 Auxiliary Power Supply :

(i) Motors rated 1500 KW &

above.

: 11000 V (±10%), 3 phase, 3W, 50 Hz,

non-effectively earthed.

(ii) AC motors at 200 KW &

below 1500 KW.

: 3300 V (±10%), 3 phase, 3W, 50 Hz,

non-effectively earthed.

(iii) AC motors upto 200 kW. : 415 V, (±10%), 3 phase, 3 wire, 50 Hz,

effectively earthed

(iv) DC alarm control & Protective

devices.

: 220 V DC, 2W, unearthed

(v) DC motors. : 220 V (±10%), 2 wire, unearthed DC

(vi) Lighting fixture and Space

Heaters.

: 240 V, 1 phase, 50 Hz, AC effectively

earthed

(vii) DCS Power supply : 240 V AC, 1 phase, 50 Hz, UPS

(viii) Solid state controls &

annunciation/ local control

panel

: 240 V AC, 1 phase, 50 Hz, non UPS

(ix) Construction Power : 415 V (±10%), 3 phase, 4 wire, 50 Hz


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±5%, AC with effectively earthed

8 Suitability for Power Supplies

:

(i) AC Supply : Voltage variation ±10%,

Frequency variation ±5%;

Combined Voltage and Frequency

variation 10%

(ii) DC Supply : 198 V to 242 V

9 Design Ambient for Electrical Equipment

: 50.0 degree C

3.00.00 REFERENCE DOCUMENTS-: CODES & STANDARDS

IS-1554-1 : PVC insulated electric cables for working voltages up to and

including 1100V.

IS-7098-1 : Cross linked polyethylene insulated PVC sheathed cables

for working voltages up to and including 1100V.

IS:7098-II : Cross linked polyethylene insulated PVC sheathed cable for

working voltage from 3.3kV upto & including 33 kV.

IS:9968-I : Specification of Elastomer Insulated cables for rated

voltages upto and including 1100V

IS:6380 : Specification of elastomeric insulation and sheath of electric

cables

IS : 3961 : Recommended current ratings for cables

IS : 3975 : Low Carbon Galvanized steel wires, formed wires and tapes

for armouring of cables.

IS : 5831 : PVC insulation and sheath of electrical cables.

IS : 8130 : Conductors for insulated electrical cables and flexible cords.

IEC:287 : Calculations of the continuous current rating of cables(100%

load factor)

IEC:228 : Conductors for insulated cables

IEC:502

: Extruded solid dielectric insulated power cables for rated

voltages from 1.00 kV upto 30 kV

IEC-754-I : Test on gases evolved during combustion of electric cables.

IEEE-383 : Standard for type test of Class IE Electric Cables.

IEC -332 Tests on Electric cables under fire conditions.


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Part-3 : Tests on bunched wires or cables (category -B)

IEC: 230 Impulse tests on cables and their accessories

IEC-331 Fire resisting characteristics of electric cables

IEC-364-5-

52

Current-carrying capacities in wiring systems-Section 523

Second Edition 2001-08

4.00.00 CABLE SELECTION AND SIZING CRITERIA

4.01.00 Cable sizing criteria for Power cable

The calculation and technical choice of power cables consist of the determination of the normalized conductor in applying simultaneously the three following conditions:

a) Continuous current capacity: The overheating, in permanent overload (thermal

protection current setting), taking into account the site and installation conditions, so

that cable components are not exposed to excessive temperature value.

b) Short time rating: The possibility to carry without degradation, an accidental over

current at the end of the cable, taking into account protection devices.

c) Voltage drop criteria: The voltage drop caused by the current flowing in cores

restricted to a value allowing the starting and the permanent loading of the consumers.

The conditions (a) and (b) give the minimal cross section of the conductor. Condition (b) will be applied for all HT feeders and for feeders controlled by ACB’s in case of LV system. Cables shall be sized for rated short circuit current of the respective Swgrs/Boards/MCCs. Feeders controlled by fuses/MCB’s/MCCB’s will not be sized for short circuit rating.

The condition (c) gives the maximum length, which can’t be exceeded, in order to comply with the maximum admissible voltage drop. If the length permitted by conditions (c) is insufficient, it will be necessary to increase the cable cross-section consequently.

5.00.00 ELECTRICAL NETWORK CHARACTERISTICS

5.01.01 Electrical Network Characteristics

A For HT system

Rated voltage (General network) : 11 kV AC 3 phase & 3.3 kV AC 3 phase.

Frequency : 50 Hz

Maximum Voltage drop in the

cable from transformer to

Panel.

: 2% (rated conditions)


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cable from Panel to Motor

: 3% (full load running conditions)

Maximum voltage drop in the

cable during starting of motor. :

15%

Short Circuit Current for HT

Switchboard. :

40kA for 1 sec for both voltage grading.

(Shall be decide as per short circuit study)

Calculated Maximum Short

Circuit Current. : As per short circuit study

B For LT system

Rated voltage (General network) : 415 V AC three phase / 240V AC Single phase

/ 220V DC.

Frequency : 50 Hz


cable from transformer to MCC. : 2% (rated conditions)


cable from MCC to Motor. : 3% (full load running conditions)

Maximum voltage drop in the

cable during starting of motor. : 15%

Maximum voltage drop from

UPS to load end. 5% (full load running conditions)

Short Circuit Current for LV

Switchboard :

50 /65 kA rms

(Shall be decide as per short circuit study)

Calculated Maximum Short

Circuit Current. : As per short circuit study

6.00.00 TECHNICAL REQUIREMENT OF CABLES

A.For HT System

Core : Single/Multi core, Multi stranded bare

Aluminum

Shape of conductor : Compacted Round

Grade : 11/11(UE) kV for 11 kV System & 3.3/3.3

(UE) kV for 3.3 kV System.


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Conductor Screen : Triple Extruded semi-conducting

compound.

Insulation : Extruded XLPE

Insulation Screen : Extruded semi-conducting compound in

combination with a layer of lapped copper

tape.

Maximum permissible conductor

temperature:

A ) For continuous operation

B ) Short circuit condition

:

:

90 deg C

250 deg C

Inner sheath : Extruded PVC Compound type ST-2

Armouring (Directly buried cable)

A ) For single core cable

B ) For multi core cable

Aluminium round wire Galvanised steel round wire

External sheath : Extruded FRLS, anti termite & anti rodent

PVC type ST-2. Flame retardant property

shall be as per IEC-60332 Cat C.

Oxygen index : Min. 29 (As per ASTMD 2863)

Acid gas emission : Max. 20% (As per IEC-754-I)

Smoke Density : Light transmission of min. 40% after the

Test.

** For Cable area >= 240 sqmm, shall be considered as single core cable.

B. For LT System (Power Cable)

Core : Single core/ Multi core, Multi-stranded

bare compacted plain aluminium

for sizes greater or equal to 6 sq. mm.

Less than 6 sqmm shall be copper

Conductor.


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Grade : 1100 V

Insulation XLPE:- For area >= 120 sqmm.

PVC:- For area < 120 sqmm

Maximum permissible conductor

temperature:



90 deg C for XLPE, 70 deg C for PVC

250 deg C for XLPE, 160 deg C for PVC

Inner sheath Extruded PVC compound type- ST2 for

XLPE insulated cable.

Extruded PVC compound type- ST1 for

PVC insulated cable.

Armouring (Directly buried cable)

A ) For single core cable

B ) For multi core cable

Aluminium round wire Galvanised steel round wire

External sheath Extruded FRLS, anti termite & anti rodent

PVC compound type- ST2 for XLPE

insulated cable. Flame retardant property


Extruded FRLS, anti termite & anti rodent

PVC compound type- ST1 for PVC

insulated cable. Flame retardant property


Oxygen index Min. 29 (As per ASTMD 2863)



Test.

Cores of the cables shall be identify by coloring of insulation. Following color scheme shall be adopted:

1 core - Black

2 core - Red & Black

3 core - Red, Yellow & Blue


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4 core - Red, Yellow, Blue and Black

For reduced neutral conductors the core shall be black.

** For Cable area >= 240 sqmm, shall be considered as single core cable.

C. For Control Cables

Core : Multi stranded plain annealed copper.

(Class-2 as per IS 8130)

Shape of conductor : Circular

Conductor cross section : 2.5 sq. mm

Grade : 1100 V

Insulation : Extruded PVC compound type-A

Maximum permissible conductor temperature:



: 70 deg C : 160 deg C

Inner sheath : Extruded PVC compound type ST-1

Armouring ( Directly buried cable) For multi core cable

: Galvanised steel round wire

External sheath

: Extruded FRLS, anti termite & anti rodent PVC compound type –ST1. Flame retardant property shall be as per IEC-60332 Cat C.

Oxygen index

: Min. 29 (As per ASTMD 2863)



Test.

Cores of the cables of upto 5 cores shall be identified by colouring of insulation. Following colour scheme shall be adopted.

2 core - Red & Black

3 core - Red, Yellow & Blue

4 core - Red, Yellow, Blue and Black


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5 core - Red, Yellow, Blue, Black and Grey

For cables having more than 5 cores, core identification shall be done by numbering the insulation of cores sequentially, starting by number 1 in the inner layer (e.g. say for 10 core cable, core numbering shall be from 1 to 10). All the numbers shall be of same color. The color of insulation for all cores shall be grey only.

7.00.00 SIZING OF POWER CABLE

A. Cable sizes based on short circuit current consideration

Short circuit current and the time duration are related with the following formula :

I12t1 = I2

2t

Where,

2

I1 = Short circuit current for t1

I

second

2 = Short circuit current for t2

The short circuit current & interrupting time shall be as under:

second

1. For 11kV – 40kA – 0.2 sec for outgoing motor feeders.

40kA – 0.2 sec for outgoing transformer feeders

40kA – 1 sec for tie feeders

2. For 3.3kV – 40kA – 0.2 sec for outgoing motor feeders

3. For 415V--- 50/65kA – 0.2 sec for outgoing motor feeders

50/65kA – 0.2 sec for outgoing transformer feeders

50/65kA – 1 sec for tie feeders

For Fuse/MCB/MCCB protected feeders, minimum cross section criteria will not apply. In

that feeders continuous current rating and voltage drop will be the deciding factor for

selecting the suitable cables.

Also Outgoing feeders where only IDMTL protection is provided, 1 sec shall be considered

for cable sizing.

With the above formula the equivalent fault current for 1 second is calculated and the

corresponding cable cross sectional size is selected from cable catalogue.

B. Cable sizes based on maximum continuous load current

(1) The allowable continuous current rating of cable shall be calculated using the

following formula:


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Io ≥ Ie / K

R

Where

Io - Allowable continuous current rating of cable in Amps

Ie - Rated current of equipment in Amps

KR

Cables

- Overall Derating factor due to temperature and grouping of

(2) Derating factors

a) Ambient temperature derating factor : K

T

3 - 21 - 2 = KT ΘΘ

ΘΘ

Θ2 = Core maximum temperature (90° C for XLPE insulation)

(70° C for PVC insulation)

For cables in trays, trenches, racks

Θ 1 = Design temperature for aerial cables: 50° C

Θ 3 = Reference ambient air temperature: 40° C (as per vendor catalogue)

40 - 9050- 90 = KT = 0.89 (For XLPE cable)

40 - 0750- 07 = KT = 0.81 (For PVC cable)

For cables laid directly in ground

Θ 1 = Design temperature for aerial cables: 40° C

Θ 3 = Reference ambient ground temperature: 30° C (as per vendor catalogue)

30 - 9040- 90 = KT = 0.91 (For XLPE cable)

30 - 0740- 07 = KT = 0.86 (For PVC cable)

b) Cable Group derating factor: KL

This factor depends on the type of laying (touching / spaced), type of cable (single / multi


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core), number of trays and number of cables.

The cable group derating factor is considered in line with manufacturer`s catalogue & the

same is attached as ANNEXURE-I. As per manufacturer`s recommendations, the group

derating factor for cables in cable trays are listed below.

Sl. No.

Type of Cable Type of laying Group Derating Factor

(KL)

1 Single Core

Cables

Trefoil formation with 2

Dia Spacing 0.79

2 Multi Core

Cables Touching Formation 0.66

3

Single core

cable directly

laid in ground

Touching formation 0.73

4

Multi core

cable directly

laid in ground

Touching Formation 0.75

c) Overall Derating Factor: KR

Overall Derating factor (K

For cables in trays, trenches, racks

R ) = Temperature Derating factor (KT

Group Derating Factor (K

) X

L

Sl.No.

)

Type of Cable

Type of laying Overall Derating Factor (KR) for

XLPE cable

Overall Derating Factor (KR) for

PVC cable

1 Single Core

Cables

Trefoil formation

with 2 Dia

Spacing

0.70

Not required

2 Multi Core

Cables

Touching

Formation 0.59

0.53


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Overall Derating factor (K

For cables laid directly in ground

R ) = Temperature Derating factor (KT

Group Derating Factor (K

) X

L

Thermal resistivity of soil.

) X Derating for depth of laying X

For 11kV / 3.3kV cables, depth of laying is considered as 0.9M as per IS 1255 and Thermal

resistivity of soil is 2000

Sl.No.

Ccm/W (assumed). Based on Manufacture’s catalogue attached in

Annexure-1, derating factor for depth of laying and thermal resistivity of soil are considered

1 & 0.89 respectively.

Type of Cable

Type of laying Overall Derating Factor (KR) for

XLPE cable

Overall Derating Factor (KR) for

PVC cable

1 Single Core

Cables

Spacing of 45cm

between trefoils,

directly laid in

ground

0.59 Not required

2 Multi Core

Cables

Spacing of 45cm

between trefoils,

directly laid in

ground

0.60 0.57

(3) Rated Current Computation:

The rated current (Ie) of the equipment shall be calculated using the following equation.

(a) At normal operation. P x 1000 Ie =

Ki x V x η x Cosθ Where:

Ie = Rated current of equipment in Amps.

P = Rated output of equipment in kW

V = Rated voltage in Volts.

η = Efficiency.

Cosθ = Power factor.

Ki = Coefficient


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(b) At starting of the motor

Is = Ks x Ie Where:

Is = Starting current of motor

Ks = Starting current ratio

The rated values of equipment (Ie, Is, Cosθ etc.) shall be obtained from the single line

diagrams, motor data sheet etc. or the same may be taken as per Table-1.

TABLE-1

RATED CURRENT OF EQUIPMENT

ITEM 415V / 240V MOTOR

MOTORISED VALVES & DAMPERS

TRANSFORMER & OTHER FEEDERS

DC MOTOR

& FEEDER

S SYSTEM AC DC CIRCUIT 3φ 3W 1φ2W 1φ2

W 3φ3W & 4W 1φ 2W

Ki √ 3 1 1 √ 3 1 RATED

CURREN

T (AT

NORMAL

OPERATI

ON) , Ie

(Amps)

P (kW)

P x 1000

√ 3 x V x η x Cosθ

Px1000

V x η x Cosθ P x1000

√3xVxηx Cosθ

Px1000

V P

(KVA) P x 1000

√ 3 x V x η Px1000

V x η

Px1000

V Px1000

√ 3 x V x η

Power Factor & Efficiency

P(kW) η Cosθ P(kW)

η Cosθ ηxCosθ ηxCosθ ηxCosθ

<2.2 0.65 0.8 <2.2 0.65 0.65 1

0.8

1 >2.2 to

<15 0.85 0.8 >2.2 0.85 0.65

>15 to <90

0.93 0.8

>90 0.94 0.85 Ks 6.0 6.0

1.0 2


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For 11Kv / 3.3kV MV Motors, efficiency of 0.95 and power factor of 0.9 can be considered and the starting current can be taken as 6 times of full load current for motor rated upto and including 1500kW, 5 times of full load current for motor rated above 1500kW and 4.5 times of full load current for motor rated above 5000kW.

NOTE : THE ABOVE DATA IS BASED ON INFORMATION FROM VARIOUS MANUFACTURERS

AND OUR STANDARDS USED FOR VARIOUS PROJECTS.

C. Cable sizes based on voltage drop calculation criteria

The allowable voltage drop of cable over the rated voltage of equipment shall be limited to

2% between Transformer to MCC and 3% between MCC to Motor at full load running

condition and 15% during motor starting condition. Lighting cables shall be sized to limit the

voltage drop from main lighting distribution board (MLDB) to lighting panel (LP) as 3%.

The voltage drop is calculated using the maximum size calculated in 7.00.00(A) and

7.00.00(B) above by the following formula.

(a) At normal/running operation

Vn = Kv x Ie x L x (R Cosθ + Xc Sinθ)

(b) At starting of motor

Vs = Kv x Is x L x (R Cosϕ + Xc Sinϕ) Where:

Vn, Vs = Voltage drop of cable

Kv = Coefficient

Ie = Rated current of equipment

Is = Starting current of equipment

L = Length of cable in KM

R = Resistance of cable (Ω / Km) at max continuous

temperature of conductor Rac- for AC circuit & Rdc- for

DC circuit

Xc = Cable reactance (Ω/ Km)

Cosθ = Normal/running Power factor

Cosϕ = Starting Power factor


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TABLE-2

VOLTAGE DROP IN THE CABLE

ITEM 415V MOTOR MOTORISED VALVES

&

DAMPERS

TRANSFORMER &

OTHER FEEDERS

DC MOTOR &

FEEDERS

SYSTEM AC DC

CIRCUIT

3φ 3W

1φ 2W

1φ 2W

3φ 3W &

4W

1φ 2W

Kv √ 3 2 2 √ 3 2

VOLTAGE

DROP OF

CABLE

(V)

Vn

AT NORMAL OPERATION

√3 x Ie x L x (Rac Cosθ+ Xc

Sin θ )

AT NORMAL OPERATION

2 x Ie x L x (Rac Cosθ+

Xc Sin θ )

2 x

Ie x Lx

(Rac Cosθ

+

Xc Sin θ )

√3 x

Ie x Lx

(Rac Cosθ +

Xc Sin θ )

2x Ie x L x Rdc

Vs

AT STARTING OF THE

MOTOR

√3 x Is x L x (Rac Cosϕ+ Xc

Sin ϕ )

AT STARTING OF THE

MOTOR

2 x Is x L x (Rac Cosϕ+

Xc Sin ϕ )

For Motor feeders

2x Is x L x Rdc

POWER FACTOR

Cosθ

&

Sin θ

P

KW

Sinθ Cosθ P

KW

Sin θ Cosθ

Sin θ = 0.52

Cosθ = 0.85

----

AT NORMAL OPERATION

<90

0.6

0.8

<2.2

0.76

0.65

>90

0.53

0.85

>2.2

0.76

0.65

AT STARTING OF MOTOR

----

----

<90

0.93

0.35

<2.2

0.76

0.65

>90

0.95

0.30

>2.2

0.76

0.65

For 11Kv / 3.3kV MV Motors, running power factor of 0.9 and starting power factor of 0.3 will be considered. NOTE : THE ABOVE DATA IS BASED ON INFORMATION FROM VARIOUS MANUFACTURERS AND

OUR STANDARDS USED FOR VARIOUS PROJECTS.


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8.00.00 SIZING OF CONTROL CABLE

Minimum size proposed for control cables will be 1.5 sq. mm. For current transformer secondary circuits 4.0 sq. mm minimum cross section shall be used for each phase and for potential transformer secondary circuits, the minimum cross section of the conductors shall be 4 sq. mm. The minimum number of spare cores in control cables shall be as follows:

No. of cores in cable

2C, 4C NIL

Min. No. of spare cores

5C-6C 1

7C-13C 2

14C & above 3

9.00.00 CONCLUSION

According to 7.00.00(A) & 7.00.00(B) calculations the cable cross section is sufficient to

carry the current during normal as well as short circuit conditions.

As per 7.00.00(C) calculation the cable voltage drop with the cross sections calculated will

always be limited to 2-3% during normal operation and 15% during the motor starting

condition.

The above criterion defines the basis for selection and sizing of the cables. For package

vendors, this will be used as a broad guideline. The final selection of the cables shall be the

maximum of the sizes calculated according to 7.00.00(A),(B) &(C) and shall be standardized so

as to optimize the number of cables sizes proposed for this project. The cable sizing calculation

shall be submitted as a separate document.

ANNEXURE-I

Sheet 1 of 2

srprasad

Rectangle

ANNEXURE-I

Sheet 2 of 2

srprasad

Rectangle

Documents

DBR_Cable Selection and Sizing_E-TSC1-725!14!3001