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Introduction
There are several aspects of selecting cables for a given application. Among the most important are the following: type of installation or laying conditions, voltage rating, ambient conditions, and the most important aspect, ampacity. The more complicated issue in cable selection is choosing on the basis of ampacity. The Philippine Electrical Code (PEC) has specific rules for calculating ampacity requirements for branch circuits and feeders Having calculated the required ampacity, the next step is to select the cable type. After selecting the type the next step is to carefully determine the cable ampacity corrected for variant conditions of installation intended for the cables use.
Cable Selection
Cable Selection Cable selection involves carefully considering the following factors:
Voltage
Cables are rated for a certain voltage of application. Common building wires are rated for 600 Volts. In the Code, generally, rules of application are divided into for cables 0 to 2000 Volts and for cables over 2000 Volts. Choose the cables appropriate for the intended use.
Cable Selection
Choosing the insulation type necessitates knowing the
following:
Cable Selection
Terminal provisions of connected equipment
Those rated 100 A or less or marked for 38 sq mm or less shall have conductors rated 60C connected to them; conductors rated 75C can be used if the ampacity is determined at 60C rating. Those rated more than 100 A or marked for more than 38 sq mm shall be allowed to have 75C rated conductors connected. Higher temperature rating conductors shall be allowed if their ampacities are determined at 75C. Higher conductor ratings may be used if the equipment is listed and identified for use with such higher temperature
Cable Selection
Cable Selection
Cable Construction
This factor will be determined primarily by the design installation conditions. This factor consists of the following:
Whether solid or stranded, for small conductors Whether a jacket is applied over the insulation, over a
set of conductors, or over armoring Whether the cable is single conductor or multiconductor For multiconductors, the number of core conductors For multiconductors, whether the ground wire and/or the neutral is integrated with the cable
Cable Selection
Additional covering or whether shielding and/or armoring
or metal sheathing is desired: shielding is basically for electromagnetic isolation, armoring is for mechanical protection while metal sheathing provides water-tight protection. For example, lead sheathed cables are common in the petroleum industry.
Cable Selection
Ampacity The most important factor to consider is cable ampacity. Basically, it should match the requirement of the circuit, that is, the demand of the load. After the ampacity is determined, the following conditions should then be checked and the size of the conductor adjusted as necessary:
Cable Selection
The basic rule in the Code is that conductors shall be
protected against overcurrent at their derated ampacities. Protective device rating. The PEC states that The next higher size of protective device rating shall be permitted for ampacities 800 amperes or less. The next higher size of protective device shall be used for ampacities higher than 800 amperes.
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Ampacity -- Definition
Ampacity is defined in the PEC (Article 1.1.1) as the current, in amperes, that a conductor can carry continuously under the conditions of use without exceeding its temperature rating. This definition gives us the following points to consider: 1. Ampacity is a continuous current rating of the conductor; 2.The conditions of use MUST be specified, 3. The conductors temperature rating MUST not be exceeded
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Ampacity -- Definition
The mechanics for the rise in temperature in a conductor must also be understood to fully appreciate the limitations and imposed by the conditions of use on cable ampacity.
Consider a conductor with resistance R carrying an amount of impressed current I. The current will generate heat within the conductor at the rate P according to the following power formula P = I2R. To a lesser degree heat is also generated by induced currents in the other metallic components of the cable, if present. Among these are metallic sheaths and armors
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Ampacity -- Definition
Losses in the dielectric materials surrounding the
conductor also contribute to heat generation (insulation, shields, screen, jacket and serving/bedding) nearby) contribute heat to the conductor as well as to the environment surrounding that conductor
conductor material. With a sufficient combination of current and time, (I2t), the conductor, and its insulation will attain a higher temperature than the ambient (air or soil).
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Ampacity -- Definition
The difference in temperature gives rise to the transfer of
heat from the cable to the environment. This transfer occurs by way of conduction, convection and radiation Conduction is the transfer of heat from molecule to molecule and generally occurs predominantly if the material surrounding or touching the cable is solid, such as earth Convection occurs if the material surrounding the cable is a moving fluid such as air, oil or water. Convection is the transfer of molecules (and therefore with it, heat) either by bulk or significant diffusion Thermal radiation is another mode of heat transfer although a less significant one under normal temperature ratings
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Ampacity -- Definition
Generally all modes of heat transfer operate. Conductors in
a raceway in earth will have convection operating in the air within the duct and conduction from the duct to the earth
affected by temperature difference as well as the thermal barriers between the conductor and the environment. Thermal barriers include the insulation, jacketing, air inside raceway, the raceway itself, soil, concrete, building materials, and any thermal insulation applied such as fireproofing.
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Ampacity -- Definition
If an equilibrium is attained between the rate of heat transfer
and the rate of heat generation, a steady state temperature is achieved by the conductor which is also the temperature at the boundary with the insulation. developed within it. However, the insulation enclosing the conductor has temperature limits as determined by its thickness and composition
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Ampacity -- Definition
This limit is termed the conductors maximum operating
temperature.
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Conductor characteristics
a. Conductor material b. Conductor size
Insulation characteristics
a. Type of material b. Thickness
Construction
a. Single conductor or multi-conductor b. Presence of jacketing, coverings, sheathing and armoring
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with a resistivity of 1.68 x10-8 ohmm at 20oC, and aluminum with a resistivity of 2.82 x10-8 ohmm at 20oC
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insulation. The PEC specifies required insulation thicknesses for listed insulation types. The thicker the insulation, the better it can withstand an applied voltage before breaking down, so generally, the higher the conductors voltage rating the thicker the insulation. Aside from providing electrical isolation, insulation should also provide some mechanical protection
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and 3.10.1.64 list approved insulation type and thickness for various cable insulations. In fact the code defines insulated conductor as one encased within material of composition and thickness that is recognized by the code as electrical insulation. This recognition is documented in these tables. Conductors not meeting the required insulation type and minimum thickness of encasing material are classified as covered conductors only.
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transferred to the environment and can be one of the following: Free air Directly buried in earth Enclosed type of installations restrict the flow of air
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raceway nor routed underground and allows the air to flow freely. With this type of installation, cable conductors can more easily cool to the ambient air, temperature. Installation of this type can be one of the following: Open Wiring on Insulators - An exposed wiring method using single insulated conductors supported on insulators run in or on buildings. Messenger Supported Wiring - An exposed wiring support system using messenger wire to support insulated conductor. Cable Tray Ladders and ventilated troughs allow free flow of air around the conductors (However, covered solid bottom cable trays restrict the flow of air by practically enclosing the conductors)
*** COMPANY CONFIDENTIAL *** 2012 Fluor Corporation 32
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Ampacity Determination
The PEC allows two methods of determining ampacity of cables
1. By use tables of cable ampacities 2. By calculation under engineering supervision using the Neher-McGrath equation
There are twenty six (26) ampacity tables in the PEC, six for
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The use of the PEC ampacity tables require understanding the conditions under which the tables were developed. Deviations from the defined conditions require the application of adjustment factors, specifically for ambient temperature and installation condition including grouping.
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PEC. Below is the tabulated data for ampacity Tables 3.10.1.16 to 3.10.1.21
Table No. Conductor Temperature Construction / Grouping Insulated conductors, not more than three current-carrying conductors Single-insulated conductors Insulated conductors, not more than three current-carrying conductors Conductor Type Copper/Aluminum or copper-clad aluminum Copper/Aluminum or copper-clad aluminum Copper/Nickel or nickel-coated copper/Aluminum or copper-clad aluminum Installation Condition Installed in raceway, cable, or earth (directly buried) Free air Ambient Temperature 300C
3.10.1.16
60-75-90 C
3.10.1.17
60-75-90 C
300C
3.10.1.18
150-2500C
Raceway or cable
400C
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3.10.1.19
Free air
3.10.1.20
75-900C
400C
3.10.1.21
80 C
400C
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There are twenty ampacity tables for cables rated 2001 35,000V in the PEC. Below is the tabulated data for ampacity Table 3.10.1.67 to 3.10.1.86
Table No. 3.10.1.67 3.10.1.68 3.10.1.69 3.10.1.70 3.10.1.71 3.10.1.72 3.10.1.73 3.10.1.74 3.10.1.75 3.10.1.76 Conductor Temperature 90-1050C 90-1050C 90-1050C 90-105 C 90-1050C
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Construction Insulated single conductor cables Insulated single conductor cables Insulated threeconductor cables Insulated triplexed or three singleconductor cables Insulated threeconductor cables
Conductor Type Copper Aluminum Copper Aluminum Copper Aluminum Copper Aluminum Copper Aluminum
Installation Condition Triplexed in air Isolated in air Isolated in air Isolated conduit in air Isolated conduit in air
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3.10.1.78
Aluminum
200C
200C
90-1050C
200C
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Conductor Temperatur e
Construction Three insulated conductors cabled within an overall covering (threeconductor cable) Three triplexed single insulated copper conductors
Installation Condition
Directly buried in earth Directly buried in earth, RHO of 90, 100% load factor
200C
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of the 2009 PEC. These tables, summarized below, are not part of the Code per se but they provide ampacity information for conditions not described in the tables within the Code.
Conductor Temperature Construction / Grouping 2 to 3 Insulated conductors, with overall covering (multiconductor cable) Multiconductor with at most 3 Insulated conductors Single Insulated conductors Installation Condition Ambient Temperature In air (UON) 300C
B-310-1
60-75-90 C
60-75-85-900C B-310-3 (cable type TC, MC, MI, UF and USE) 750C
In Free air
400C
B-310-5
200C (earth)
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Construction / Grouping Three-Conductor Cable Three Single Insulated conductors 2 to 3 Insulated conductors, with overall covering (multiconductor cable) 3 triplexed single insulated conductor Three Single Insulated Conductors
Installation Condition In Underground duct (one cable per duct) In Underground duct (three conductors per duct) Directly Buried, 100% Load factor, RHO of 90 Directly Buried, 100% Load factor, RHO of 90 Directly Buried, 100% Load factor, RHO of 90
B-310-6
B-310-7
75 C
200C (earth)
B-310-8
60-75 C
200C (earth)
B-310-9
60-75 C
200C (earth)
B-310-10
60-750C
200C (earth)
Note: For underground duct and directly buried cables, see Figure B-310-2 of the PEC for cable installation dimensions.
*** COMPANY CONFIDENTIAL *** 2012 Fluor Corporation 45
very specific parameters described above. Some of these (voltage, maximum operating temperature, conductor material, construction) are either inherent characteristics of the cable or are designated by the manufacturer based on standard tests. They are the first filters to be used when selecting cables.
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the ampacity tables. Any deviation from these parameters can mean one of the following: 1. The table is not applicable 2. The table is applicable but adjustment factors have to be used
There are two parameters for which deviations from the listed
condition in the NEC ampacity tables can be compensated (or will be modified) by use of adjustment factors: 1. Ambient temperature (air or earth) 2. Grouping and/or installation conditions
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Using the PEC Ampacity Tables - Adjustment Factors for Ambient Temperature
For cables rated 0 to 2000 V, the adjustment factors for deviations
from listed ambient are tabulated at the bottom of each ampacity table. Below is an example for the factors for table 3.10.1.16
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Using the PEC Ampacity Tables - Adjustment Factors for Ambient Temperature
For cables rated over 2000 V, the adjustment of ampacity for
deviations from listed ambient are determined from the following formula:
I 2 I1
Where I1 = Ampacity from tables at ambient TA1 I2 = Ampacity at desired ambient TA2 TC = Conductor temperature in degrees Celsius (oC) TA1 = Surrounding ambient from tables in degrees Celsius (oC) TA2 = desired ambient in degrees Celsius (oC) TD = Dielectric loss temperature rise
TC TA 2 TD TC TA1 TD
Note that the same formula is valid for cables rated for 0 to 2000 volts by ignoring the terms TD, the dielectric loss temperature rise.
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Thus the table is expressed as valid for one to three current carrying conductors in raceway, cable or earth (directly buried)
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3.10.1.16
60-75-90 C
300C
3.10.1.18
150-2500C
Raceway or cable
400C
In Free air
400C
B-310-3
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3.10.1.17
60-75-90 C
Single-insulated conductors
Copper/Aluminum or copper-clad aluminum Copper/Nickel or nickel-coated copper/Aluminum or copper-clad aluminum Copper/Aluminum or copper-clad aluminum
Free air
300C
3.10.1.19
150-2002500C
Single-insulated conductors
Free air
400C
3.10.1.20
75-90 C
Supported on a messenger
400C
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Conductor Temperature
Construction
Installation Condition
Ambient Temperature
400C
400C
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Conductor Temperature
Construction
Installation Condition
Ambient Temperature
400C
400C
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conductors in a raceway or cable shall NOT be applied IF the number of conductors is 30 or less. Conductors for signaling, control or communication are not counted as current-carrying conductors. For strut-type channel, and surface metal raceways, an additional condition for the derating NOT apply is that the channel or surface raceway have cross sectional area of at least 2500 sq mm.
Non-metallic auxiliary gutter, non-metallic wireway are not exempted from the application of the derating factor, regardless of the fill or number of conductors.
*** COMPANY CONFIDENTIAL *** 2012 Fluor Corporation 64
Neher-McGrath Equation
The Neher-McGrath equation is another method that can be used in calculating for cable ampacity under engineering supervision as the PEC requires. The Neher-McGrath formula is a heat transfer formula, comprising a series of heat transfer calculations, that takes into account all heat sources and the thermal resistances between the heat sources and free air. The most common use of this formula is to calculate for the ampacity of conductors in underground electrical ducts (raceways), although the formula is also applicable to all conductor installations.
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directly dependent on the difference in temperature between the conductor (TC) and the ambient (TA). In a heat transfer equation TC-TA = (I x I x R) x RCA, where I is current in amperes, R is electrical resistance in ohms, and RCA is thermal resistance in degrees Centigrade-cm/watt usually called thermal-ohm-feet. TC is the maximum permissible operating temperature in degrees Centigrade of the conductor. TA is the ambient temperature of the air or soil for underground installations. Solving for I:
TC TA RxRCA
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TC TA TD I ( RDC1 YC)RCA
Where: I = Ampacity, (kA) TC = Conductor temperature, (C) TA = Ambient temperature in C TD = Conductor temperature rise due to dielectric loss, (C) RDC = Conductor dc resistance, (/m) YC = Loss increment due to conductor skin and proximity effects RCA = Thermal resistance between conductor and ambient, (thermal -m)
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and presented in a paper entitled The Calculation of the Temperature Rise and Load Capability of Cable Systems to AIEE (American Institute of Electrical Engineers) the precursor to the organization IEEE.
In this equation, TD, is a term added to the ambient
temperature, TA, to account for the heat generated in the insulation and other covering of dielectric material. It represents the temperature rise arising from dielectric loss. It is insignificant for voltages below 2000. Another term in the NM equation, (1+YC), is a multiplier to convert direct current resistance (RDC) to alternating current resistance. For small wire sizes this term becomes insignificant.
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application to actual cable configurations can be daunting. Appendix B of the PEC contains ampacity tables developed using the Neher-McGrath equation. Power systems software like ETAP and EDSA use the Neher-McGrath equation, as well as equivalent in an IEC standard.
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Conclusion
Wiring is a very significant part of our work. One of the basic
responsibilities of the electrical engineer or electrician is to ensure electrical installations are safe. Whether as engineering designers, constructors, equipment manufacturers, or maintenance personnel, we have the obligation to ensure that our wiring design and installations are correct according to the Code. It behooves us therefore to make sure that cables we use are properly selected and sized for use.
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Q&A
QUESTIONS?
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References
Philippine Electric Code 2009 National Electrical Code, 2005 Mike Holt Enterprises Website National Electrical Manufacturers Association (NEMA) http://neher-mcgrath.com
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