UNDERGROUND DUCTBANK

HEATING CONSIDERATIONS

A Practical Approach to Determining

UG Electrical Ductbank Ampacity
Mike Mosman, PE
CCG Facilities Integration Incorporated

March 2016

© CCG Facilities Integration Incorporated

Topics
2

ˆ PHYSICS of HEAT in DUCTBANKS

ˆ NEC and DUCTBANK AMPACITY

ˆ TIPS for ACCURATE AMPACITY

CALCULATIONS

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 Ductbanks Have Issues
3

ˆ What’s wrong with this picture?

‡ Maybe lots of things, maybe nothing.
ˆ One needs to know purpose and usage of ductbank before
design is deemed suitable. © CCG Facilities Integration Incorporated

4 PART ONE
The Physics of Underground
Ductbank Heating and Ampacity
Calculations
 Basic Thermodynamics
5

ˆ Heat moves from hot

things to cold things.
ˆ Heat flows through
liquids, solids and gasses
by various mechanisms.
ˆ Heat transfer rate
depends on temperature
difference and thermal
resistance.

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Heat Generation
6

i = amps

Vin Vout

ˆ Watts (W) = i2 x R = i x (Vin – Vout)

ˆ 1 Watt-second (W-s) = 1 Joule (J)
ˆ 1055.06 J = 1 BTU (British Thermal Unit)
ˆ Q = Heat, measured in Joules or BTU’s (and
sometimes calories)
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 Heat Flow
7

ˆ Q = Heat flow rate = ∂Q/∂t in J/s or BTU/h

ˆ Q = k x A x ∆T /L, with units in Watts (J/s) when:
‡ k = Thermal conductivity in W/ºC-cm
‡ ∆T = Thot – Tcold in ºC

‡ Dimensions are in centimeters (cm)

ˆ 1/k = Thermal resistance, Rho (ºC-cm/W)

A = Area (cm2)
L = Length (cm)
Q
Thot Tcold
k
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Special Considerations
8

ˆ Conductor heat
dissipation is not
4y
linear to the load.
Watts

It varies with the

square of the y

current. x 2x
Amps
ˆ Conductor impedance Silver
increases with operating Copper
Relative Impedance

temperature. (Be aware of Aluminum

temperature correction factors.)

ˆ These facts can have
significant implications in
ductbank designs.
Temperature (degrees C)
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 Heat Transfer Mechanisms
9

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Representative Ductbank
10

AMBIENT

SLABB

NATIVE SOIL

BACKFILLB

ENCASEMENTB

DUCTB

INSULATION

CONDUCTOR

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 Typical Ductbank Heat Flow
11

BACKFILL FINISHED SURFACE

ENCASEMENT

NATIVE SOIL

ˆ Encasement conducts heat from source (wires in duct).

ˆ Ultimately, almost all heat from encasement flows to surface.
ˆ Most heat flows path of least thermal resistance, which makes
backfill very important.
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Types of Heat Flow in Ductbanks

12

ˆ Radiation and conduction from surface to ambient

environment. (Lower ambient produces greater
heat flow.)
ˆ Conduction through slab or paving, if present.
(Often ignored.)
ˆ Conduction through backfill and native soil.
(Thermal resistivity, rho, of soil and backfill often
considered equivalent. Lower rho produces greater
heat flow.)
ˆ Conduction through encasement. (Thermal
resistivity, rho, of concrete often set at 55.
However, hardness and water content affect rho
values.)
ˆ Convection, radiation and conduction pass heat
from wire to duct. (Duct temperature assumed to
be that of cable surface.)
ˆ Conduction through wire insulation. (Includes
shields and outer coverings. Codes differ for LV
and MV cable types.)

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 Equivalent Circuit
13

Wire Duct Encasement Slab

Conductor Surface Surface Surface Underside
Temperature Temperature Temperature Temperature Temperature
Vc Vi Vd Ve Vs

Zb
Zi Zd Ze Zs
Duct Encasement
Zn
Insulation Slab
Backfill/Native Soil
Current Source
Amps = Heat Generated Ground = Ambient Temperature

Typical Equivalent Impedance

ˆ Volts ≈ Temperature Above Ambient (∆T)

ˆ Impedance ≈ Thermal Resistivity (rho)
ˆ Amps ≈ Heat Flow (Q)
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Thermal Models
14

SW ON
TEMPERATURE

VOLTS

COFFE TEMP

SW OFF

AIR TEMP (AMBIENT) GROUND POTENTIAL (AMBIENT)

TIME TIME

AMP
SOURCE SW Z
V VOLTS

A STEAMIN’ CUP’A JOE SIMPLIFIED EQUIVALENT CIRCUIT.

LEFT ON THE TABLE.
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 Temperature vs Time Domain
15

Load On Load Off

TEMPERATURE
T2
T1

T0 TIME
t0 t1 t2 t3
ˆ This is a typical conductor temperature vs. time curve when a
load is turned on and off, and is constant while on.
ˆ T0 is ambient (or starting) temperature. T2 is maximum
conductor temp when thermal equilibrium is reached at t2.
ˆ Load is turned off at point of thermal equilibrium and cools to
ambient at t3. (t3 - t2 = t2 - t0)
ˆ t1 is the “time constant” of this curve type. (T1 = 63% of T2)
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16 PART TWO
The National Electrical Code and
Underground Ductbank Calculations
 NEC Article 310
17

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NEC 310.15(A)(1)
18

ˆ Note – This is for low

voltage wires only.
ˆ Two methods of
calculating wire
ampacities is allowed:
‡ Tables in 310.15(B) which
are familiar to every
engineer, or
‡ Under engineering
supervision per 310.15(C)
which is basically the
Neher-McGrath formulas.
ˆ Note the reference to
Annex B.

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 NEC 310.15(A)(2)
19

ˆ There is an important Exception in 310.15(A)(2). It

will come in handy in all sorts of situations.
ˆ Note the reference to termination limitation. 90 {C
wire ampacity cannot be used with 75{C rated
terminations.
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NEC 310.15(A)(3)
20

ˆ This paragraph in the code states that the manner of use of a

conductor has a bearing on the selection of its maximum
allowable ampacity.
ˆ It is incumbent on the Engineer to determine the purpose of
the conductors in UG ductbanks, and perform appropriate
ampacity calculations that find the most economical design
that results in safe operation.
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 NEC 310.15(C)
21

ˆ This is the basis for use of the Neher-McGrath.

ˆ All is fairly simple except for determining Rca.
ˆ Thus the popularity of ampacity software.

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NEC 310.60
22

ˆ This part of the code is for medium voltage cables.

ˆ It also allows “engineering supervision,” i.e. Neher-McGrath
calculations.

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 NEC Annex B
23

ˆ When you don’t have the software and want to do quick

calculations on simple ductbanks, Annex B is a good tool.
ˆ Annex B is information and not part of the required code.
ˆ It applies to low voltage wiring (up to 2000 volts) and is not
used for MV ductbanks.
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Table B.310.15(B)(2)(7)
24

ˆ This table is used

more than all
others together.
ˆ It’s limited to just
three ductbank
configurations.
ˆ It uses “standard”
ductbank cross-
sections shown in
Figure B.310.15.

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 Figure B.310.15(B)(2)(2)
25

ˆ But what if your ductbank doesn’t look like these?

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B.310.15(B)(5)
26

AMPACITY = 2 x .88
AMAPACITY OF 1 DUCT

AMPACITY = 4 x .94
AMPACITY OF 1 DUCT IN
3-WAY DUCTBANK

ˆ What about a 5-way ductbank? Interpolation between the 4-

way (calculated) and the 6-way In chart is fairly accurate.
ˆ What about larger ductbanks?

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 Figure B.310.15(B)(2)(3) INFO
27

ˆ This figure give us a 9-way ductbank. Again, interpolation for

7-way and 8-way ductbanks is fairly accurate.

ˆ Computers required beyond

this.
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Figure B.310.15(B)(2)(1)
28

ˆ If you know how to use this

chart, you’re already expert.
ˆ The bottom half allows you to
select a different Rho value and
load factor than those given in
the Tables.
ˆ The upper half is derived from
the amperages given in the
Tables, I1 being the larger
amperage and I2 being the
smaller amperage of the three
columns of amperages.
ˆ Note the dotted line is I1, the
larger amperage.
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 B.310.15 (B)(3)(a)
29

25’
100’
ˆ Does this mean if the ductbank was 400’ long a deeper part
could be 100’? No. It’s purpose is to avoid obstructions, not to
avoid ampacity adjustments.
‡ This applies to MV ductbanks as well.
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B.310.15.(B)(3)(b)
30

-30”

BAD GOOD BETTER, BUT THE

NEC DOESN’T CARE.
‡ This applies to MV ductbanks as well.
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 Table B.310.15(B)(2)(11)
31

ˆ Account for the neutral wire if it’s current carrying.

ˆ Conductor count and ambient temp corrections must both be
applied. Why?
‡ Current carrying
neutral adds to Q, the
heat being generated.
‡ Higher ambient temp
lowers ∆T which
reduces Q, the heat
flow.
‡ More heat + less heat
flow = higher
conductor temps.

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32 PART THREE
Tips for Making Accurate and
Economical Underground Ductbank
Ampacity Calculations
 Typical Service Entrance?
33

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Complex Ductbank Problem

34

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 Is the Code Conservative?
35

ˆ Read this excerpt from the NEC Handbook – I’ll wait.

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Rho Values
36

ˆ The following (from Annex B) is a “suggestion” by the NEC,

but is it appropriate?

ˆ It’s better to verify actual conditions to be found on site. Ask

for official reports.
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 Concrete Rho Values (typical rpt.)
37

(Courtesy Near-Mcgrath.com)

ˆ Note variation of rho values with concrete encasement

hardness and water content.
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Soil Rho Values (typical report)

38

Project

ˆ Soil rho values are rarely consistent and depend heavily on

water content. © CCG Facilities Integration Incorporated
 A Word About Water Content
39

ˆ True: It never rains under a building.

ˆ False: That means it’s dry under there.
ˆ Q: Why do they put a vapor barrier under the most concrete
slabs on grade?
ˆ A: To keep the moisture from coming through the slab from
below.

Air-conditioned
building @ 70º
Parking lot @ 150º
Slab

Water evaporates ...and condenses

under hot paving under cool slab.

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“Dry” vs “Wet” Soil

40

ˆ Conduction of heat in soil occurs

at contact points between soil
particles.
ˆ Water in soil aids in conduction of
heat.
SATURATED SOIL
ˆ Saturated soils have all air gaps
filled with water.
ˆ As soil dries some water remains.
Due mainly to capillary action the
remaining water collects around
particle contact points.
ˆ Even a small amount of residual
water aids conduction at particle
“DRY” SOIL
contact points.
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 Appropriate Ambient Temperature
41

Air-conditioned
Parking lot @ 150º building @ 70º

Ambient 35ºC Ambient

(or higher?) normal 20ºC

ˆ Heat generally flows toward surface.

ˆ Ductbanks under large buildings generally remain a stable
20ºC or close to the building’s interior temperature.
ˆ Ductbanks outdoors under heat-gathering surfaces will have
higher ambient temperatures.
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Temp Adjustments in Portions

42

ˆ Wire ampacity at termination must be based on 75ºC wire, not

90ºC, due to termination.
ˆ In portion of duct near heat source temperature deration must
be applied, but it may be applied to 90ºC wire rating instead of
75ºC wire rating.

HEAT SOURCE
75ºC TERMINATION
10’

90ºC WIRE

PORTION 1 PORTION 2

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 Load Definition
43

NEC 100

NEC 210.19

NEC 220.60

ˆ These definitions imply a Load Factor effect on ampacity, but

Load Factor is not defined anywhere in the NEC.
ˆ Load Factor impact on conductor ampacity depends on what
time duration is used to define it. 3 hours? 24 hours? A
week? A year? © CCG Facilities Integration Incorporated

Beware the PVC Duct Limitation

44

ˆ Most PVC conduits are UL listed for 90ºC max wires.

ˆ 105ºC MV cables may be loaded only to 90ºC when in PVC.

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 Good Ductbank Design Practices
45

ˆ Stack ducts 2-high maximum. All ducts get proximity

to the encasement surface to facilitate heat flow.
ˆ Uneven number of ducts? Leave the blank at the
bottom middle. That’s the hottest position.

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Good Ductbank Design Practices

46

4’
OR
5’

ˆ The code allows (in Annex B) that mutual heating of

ductbanks is negligible if edges of encasements are
4’ apart or nearest conduits are 5’ apart.
‡ Only for ductbanks up to 2000 volts.
‡ This may conflict with many computerized programs.

ˆ This implies that feeders 5’ or more apart in a wide

ductbank will not mutually heat each other.
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 Non-concurrent Redundancy
47

A B A B

B A B A

ˆ When non-concurrent loads appear in same ductbank, the

code allows the calculation to be made with only the greater
load.
‡ Normal and emergency feeders to ATS’s.
‡ UPS input and bypass feeders.
‡ “A” and “B” circuits to double-corded computer equipment.
‡ Utility and backup EG feeders.
ˆ Interleave “A” and “B” circuits for cooler ductbanks.
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Short Duration Loads

48
TEMPERATURE

T2
T1 Time-domain curve

T0 TIME
t0 t1 t2
ˆ Short duration or time-limited loads may benefit from a
temperature vs. time (time-domain) ampacity calculation.
‡ Backup generator feeders, maintenance bypass feeders, etc.
ˆ T0 is ambient (or starting) temperature. T2 is maximum
conductor temp when thermal equilibrium is reached at t2.
ˆ If load is turned off before thermal equilibrium at t2, the
maximum conductor temperature T1 will be lower than T2.
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 Ampacity Software
49

ˆ When the design is complex, computerized ampacity

programs are a must. Common software programs are:
‡ ETAP (etap.com)
„ Requires add-on package for underground cable thermal calculations.
„ Add-on includes time-domain (transient) calculations.
‡ AmpCalc (calcware.com)
„ Single-purpose software.
„ Inexpensive and easy to use.
„ Does not perform time-domain calculations.
‡ CymCap (cyme.com)
„ Single-purpose software.
„ Performs time-domain calculations.
ˆ All above programs based on Neher-McGrath equations.

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50 QUESTIONS & COMMENTS

Michael Mosman, PE
VP, CTO
CCG Facilities Integration Incorporated
Baltimore, MD
(410)525-0010
MMosman@CCGfacilities.com