Underground Raceway Systems

Raceway Systems

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 2

Cable Derating Analysis

Determines the proper size of cables to carry
the specified loads for new systems.
Calculates maximum cable ampacities for
specific scenarios.
Examines cable temperatures and
ampacities for existing systems to determine
operating and emergency limits.
2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 3

Cable Derating Analysis

NEC Accepted Neher-McGrath Method
IEC 287 Method
Steady-state temperature calculation
Uniform-ampacity cable ampacity calculation
Uniform-temperature cable ampacity calculation
Cable sizing

Transient temperature calculation

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 4

Cable Ampacity
Fundamentals
Cable Ampacity is the current a conductor can carry
continuously under the conditions of use without
exceeding its temperature rating.

Heat is generated when current is carried by a

conductor since it must pass through the electrical
resistance of the conductor.
Watts = I2R

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 5

Cable Ampacity
Fundamentals
Various thermal barriers:
1. Conductor insulation

2. Air inside a duct

3. Duct wall

4. Soil surrounding an underground duct

5. Additional thermal insulation applied such as
polyurethane

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 6

Cable Ampacity
Fundamentals
Heat Transfer Equation
The rate of heat transfer is directly dependent on the difference
in temperature between the conductor (Tc) and the ambient
temperature (Ta)
Tc Ta (I 2R).RHO
RHO is thermal resistance in degrees Centigrade-cm/watt

Rearranging the terms for I:

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

( TC

TA)

( R RHO)

Slide 7

Heat Flow Model

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Slide 8

Cable Construction

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 9

Heat Flow Model

(Generalized)
Installation under an isolated
condition
Installation of groups of three
or six circuits
RHO of Soil = 90
Ta = 20 oC

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 10

Heat Transfer Problem

Ultimate Unchanged Surrounding Environment

Adjustment Factor
Heat Flow
Immediate Surrounding Environment
(Actual Installation Conditions)

In actual practice, the surrounding medium in which the cables

are to be installed rarely match those conditions under which
the stated ampacities apply.
2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 11

Adjustment Factor
Cable Derating is based on a concept of an adjustment
(multiplying) factor that is applied against base ampacity.
The multiplying factor takes into account the differences in the
cables actual installation conditions from the base conditions.

I' F x I
I = Allowable cable ampacity for the actual installation conditions
F = Cable Ampacity Adjustment Factor
I = Base Ampacity specified by cable manufacturer or NEC under an
isolated condition with a soil thermal resistively (RHO) of 90 and a
specified ambient temperature
2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 12

Adjustment Factor
Composition
F Ft x F x Fg
th
Ft = Adjustment factor to account for the
differences in the ambient and
conductor temperatures from the
base case
Fth = Adjustment factor to account for the
difference in the soil thermal
resistivity from RHO of 90
Fg = Adjustment factor to account for
cable grouping
2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 13

Duct Bank Example

I = 375 Amps 350 MCM
I = 450 Amps 500 MCM
Ft = 0.82

Ta from 20 C to 30 C
Tc from 90 C to 75 C
Fth = 0.9 RHO of 90 to 120
Fg = 0.479 350 MCM Cable
Fg = 0.478 500 MCM Cable
350 MCM
F = 0.82 x 0.90 x 0.479 = 0.354
500 MCM
F = 0.82 x 0.90 x 0.478 = 0.354
I = 375 x 0.354 = 133 Amps
I = 450 x 0.353 = 159 Amps

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 14

Neher-McGrath Equation
I
Tc
Ta
Td
Rdc
Tc
Rca

=
=
=
=
=
=
=

Tc (Ta Td)

Ampacity (kA)
I
Rdc (1 Tc) Rca'
Conductor temperature (Deg C)
Ambient Temperature (Deg C)
Conductor temperature rise due to dielectric loss (Deg C)
Conductor dc resistance (/ft)
Loss increment due to conductor skin & proximity effects
Thermal resistance between conductor & ambience (-ft)

(1+Tc) is a multiplier used to convert direct current resistance (Rdc) to

alternating current resistance or impedance. For wire sizes smaller than No. 2,
this term becomes insignificant.
TD compensates for heat generated in the jacket and insulation for higher
voltages. It is insignificant for voltages below 2kV.
2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 15

Neher-McGrath Example

Calculate ampacity of 3/C concentric stranded XHHW insulated copper

cable enclosed in a 1 inch steel conduit. Ta = 40 C
t = insulation thickness
2t = 2 x 0.045 in. = 0.09 in. [NEC Table 310-13]

DC

0.292

[NEC Table 8, Chapter 9]

DI

0.09

0.292

DI

0.382

Ri

0.012 400 log

Ri

0.56

From N-M Table VII

From N-M Table VII
a
3.2
b

1 Inch Rigid Steel Conduit ID = 1.049 in.

OD

DI
DC

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0.19
1.315

From N-M Table VII

Ds

2.16 DI

Ds

0.825

Slide 16

Neher-McGrath Example

Rsd

( n a)
Ds b

Rsd

9.457
Emissivity
Emissivity
E
0.95
Ds2
1.315 Conduit OD
Emissivity
9.5 ( n)
RE
[ 1 1.7 Ds2 ( E 0.41 ) ]
RE 7.054

Rca

Ri

Rca

17.071

Rdc75

194

Rdc90

Rdc75

Rdc90

203.402

I
I

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Rsd

RE

( 234.5
( 234.5

90 )
75 )

( 90 40 )
( 203.5 Rca)
0.12 kA with Ta = 30, I = 131 Amps
(Table 310-16 lists 130 Amps, Ta=30)

Slide 17

Cable Sizing
Determines the minimum size for each cable that will carry the
specified load current without violating the cable temperature
limit.
The sizing calculation is an
iterative process involving
adjustment of the cable size
and temperature.
Able to lock-in specific
cable sizes that cannot be
changed.

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 18

Cable Sizing Example

1.
2.
3.

Load WKSHOP-EX4
Run Load Flow
Update Cable Load Amp
(Study Case)

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 19

Cable Sizing Based Voltage Drop

Set Voltage Drop = 2%
Operating Current = 140 A
Optimal Size is Calculated
One Size Smaller is Displayed

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 20

Cable Sizing Based on Ampacity

Operating Current = 140 A
Optimal Size is Calculated

One Size Smaller is Displayed

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 21

New UGS Presentations

Project Editor Presentation Underground
Raceways - Right-Click Create New
Double-click
to change
presentation
properties

Select UGS Mode Click New Presentation

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 22

UGS Presentation
UGS presentation is
conceptually a cross-section
of cable raceways.
Each UGS presentation is a
different cross-section of the
underground system.
If you delete a raceway from a UGS presentation
into the Dumpster, the raceway can be added to
other UGS presentations as an existing raceway.
In UGS, each presentation acts independently from
each other.
2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 23

UGS Edit Toolbar

Existing Heat Sources

Existing Cables
Existing Duct Bank RWs

Existing Direct Buried RWs

New Conduits for
Duct Banks RWs
Display Options

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

New Heat Sources

New Cables
New Duct Bank RWs

New Direct Buried RWs

New Locations for
Direct Buried RWs

Slide 24

UGS Components

Heat Source

New Duct Bank RW1

Existing Cable - Pump Cable

Cable 5 cannot fit inside this
conduit and is placed outside
the conduit

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 25

Inserting Cables
Three main methods for adding cables to the existing
conduits:
1. Drag the cable from OLV
using Ctrl+Shift Key

2. Use the Existing Cable button

from the UGS Toolbar
3. Use the Routing Page from
the Cable Editor

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 26

Cable Representation
3 Conductor / Cable and
3 Conductor / Phase
Symbol: 1, 2 and 3
1 Conductor / Cable and
1 Conductor / Phase
Symbol: 1A, 1B, 1C
Single Phase Cable
Symbol: 1F, 1R
DC Cable
Symbol: 1P, 1N

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 27

UGS Example
Duct Bank
X and Y = 30
Width = 15 Height = 8

Conduit
Conduit Size = 4
Y = 3.35

Pump Cable
From OLV

New Cable
5 kV Kerite 1/C
Operating Load = 200 Amps

Run Steady-State Temp Calc

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 28

UGS Large Example

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 29

Steady-State Calculation
Calculation Pre-Requisite: All cables have been carrying the specified load
long enough that the heat flow has reached its steady-state and no more
changes of temperature will occur throughout the raceway system.

The cable temperature calculated is dependent on raceway system

configuration, cable loading, and the location of each particular cable.

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 30

Alarms and Warnings

Calculated 88.3 C is greater

Calculated 109 C is greater

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 31

Multiple Presentations

Same Cables and Heat Source

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 32

Uniform Ampacity Ampacity Calculation

Approach is based on the equal loading criterion for ampacity calculations.
Calculations determine the maximum allowable load currents when all the cables in
the system are equally loaded to the same percentage of their base loading.
Calculation Procedure
1. Determine initial loading level based on base ampacity.
2 Calculate cable temperature as in steady-state temperature calculation.
3. Check cable temperature values against the cable temperature limit.
If the temperature of the hottest cable is within close range of the temperature limit, the solution has been
reached. If not, adjust the cable loading uniformly at the same percentage, either increasing or decreasing
the loading in order to make the highest cable temperature come closer to the temperature limit. Then go
to back to step 2 to recalculate cable temperature.
The cable allowable current is updated by the calculated ampacity.

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 33

Uniform Temperature Ampacity Calculation

Approach is based on the equal temperature criterion for ampacity calculations.
Determines the maximum allowable load currents when all the cables in the system have their
temperature within a small range of the temperature limit.
In the case where these conductors are not located in the same conduit/location, they may not have the
same temperature. When this situation occurs, the temperature of the hottest conductor in this cable
branch will be used to represent this cable branch.
Calculation Procedure
1. Determine an initial loading level based on the base ampacity from the Cable Library and using cable
derating factors for the given configuration.
2. Calculate cable temperature as in the steady-state temperature calculation.

3. Check cable temperature values against the cable temperature limit.

If temperature values of all cables are within close range of temperature limit, the solution has been
reached. If not, load change required for the cable temperature to approach the temperature limit based
on the gradient of cable temperature change is determined.

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 34

Cable Sizing Calculation

The Cable Sizing Calculation determines the minimum size of each
cable that will carry the specified load current without violating the cable
temperature limit.
Only the available cable sizes within
the cable library for each selected
conductor will be considered.
Cables may be excluded if the potential
size of the cable cannot vary.
The calculation is an iterative process;
adjusting the cable size and then calculating
cable temperatures.
Once a solution is reached, calculation results will be reported in the
output report. Cables will automatically be changed to the new sizes if
the Update Size option is checked in the Study Case.
2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 35

Transient Temperature Calculation

Calculates and then plots cable temperature variations as a function of time in accordance to load changes.
(Table of Ampacity versus Time)
Provides a tool to verify operation conditions of the
raceway systems against the cable short-time or
emergency temperature limits.

Transient temperature calculations can be used to

determine the cable peak temperatures during a shorttime interval (usually less than a day), and compare
them against maximum allowable temperatures,
resulting in a more flexible and economical design of
your raceway systems.

The transient temperature calculations are based upon a dynamic thermal model of the raceway system,
constructed mainly from thermal resistance, thermal capacitance, and heat sources.
Thermal resistance is used to represent different thermal layers from cable conductor to ambient soil.

Thermal capacitance is used to represent the capability of each layer to absorb heat.
2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 36

Example From NEC

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Slide 37

NEC Duct Bank (Detail 2)

Depth= 30 in

Fill RHO = 60
1kV NEC Rubber2
1/C CU 3-phase
Magnetic
Class = 100%
Size = 350 AWG
Load = 284.5 Amps
per phase

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 38

NEC Duct Bank (Detail 3)

Depth = 30 in

Fill RHO = 60
1kVNEC Rubber2
1/C CU 3-phase
Magnetic
Class = 100%
Size = 750 AWG
Load = 334.9Amps
per phase

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 39

(Detail 2) in ETAP

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Slide 40

Results for Detail 2

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Slide 41

NEC (Detail 3) in ETAP

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Slide 42

Results for Detail 3

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Slide 43

Advanced Topics

Discussion
Exercise 1
a) Cables in the UGS presentations can be one-line view
(OLV) branch/equipment cables or UGS cables. Learn how
to route OLV cables in conduits.
b) Cable current for UGS can be user entered or ETAP
updated.
c) What is the relationship between branch loading and
conductor loading when a cable has multiple conductors
per phase?
d) The parameters that effect temperature calculations for a
given configuration are the following: ampacity, size, and
temperature.
2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 44

Advanced Topics

Discussion
Exercise 2
a) What are the differences between the two ampacity
calculation methods?
b) What are the Cable Ampacity options and usage?
c) Revision can be used to hold results for cables new
ampacities and sizes.

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 45

Advanced Topics

Discussion
Exercise 3
a) Thermal source, resistance and capacitance.
b) What is meant by initial loading?

2011 Operation Technology, Inc. PROPRIETARY & CONFIDENTIAL

Slide 46