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5143-001-CN-1621-02-A

1. SCOPE OF THE DOCUMENT



Purpose of this document is to show voltage drop calculation for all cable connections from Oil Field Substation
4,16 kV over TZC-2, TZC-3, TZC-1 to our new installed equipment. All calculations are done in accordance with
selected cable cross section and equipment ratings as shown on detailed drawings.




. REFERENCE DOCUMENTS


3. VOLTAGE DROP CALCULATION

3.1 Service VoItage at the OiI FieId Substation 35/4.16 kV Outgoing Feeder

Measured values of the maximum load current and average voltage at the Oil Field Substation 35/4.16 kV
outgoing feeder are given bellow:

- Maximum measured current
M
= 130 A
- Average measured current less than
A
= 120 A
- Average voltage U
A
= 4080 V (80 V voltage drop)

Measurements are done in period of two months (July and August). This measured values are taken as basic
parameters for detailed voltage calculations.


3. VoItage Drop CaIcuIation for the 35/4.16 kV OiI FieId Substation to TZC- CabIe Connection

Existing 5 kV Cable Parameters:

- Distance from SS Oil Substation to TZC-1 600 m
- XLPE Cable 5 kV 240 mm
2
(500 MCM)
- Resistance (90 C) R=0,0918 D/km (from Alcatel Canada Wire Catalogue)
- nductance (60 Hz) X=0,112 D/km (from Alcatel Canada Wire Catalogue)
- Maximum Current through the existing supply cable:


TOT
=
A
+
FL
= 120 + 82 = 202 A

FL
= _
FL
=
FL1
+
FL2
+
FL3
+
FL4
= 82 A

Where is:

A
average measured current (120 A)

FL1
fire motor pump current (250 kW)



FL2
and
FL3
T-02 and T-03 transformers current (transformers power 250 kVA) -
FL2
=
FL3


FL4
T-01 transformer current (transformer power 100 kVA)


- Main fire water pump full load current:

FL1
= 43 A (from fire water pump Technical data)

- T-02 and T-03 transformers full load current:

FL2
=
&
' $
c
c 3
) (

DF Demand Factor
DF = _
MFLC
/
TRSEC
= 5 x 30 (A) / 301 (A) = 150 (A) / 301 (A) = 0,49
Where is

MFLC
motor full load current (for 20 HP motors
MFLC
= 28 A from NFPA 70, table 430.150 see
attachment)

TRSEC
transformer secondary current

TRSEC
= 301
) ( 480 3
) ( 250
) ( 3
) (

c '
'
' &
' $
(A)

FL2
= 49 , 0
) ( 4160 3
) ( 250
c
c '
'
= 17 A

FL2
=
FL3
= 17 A

- T-01 transformer full load current:

FL4
=
&
' $
c
c 3
) (

DF Demand Factor
DF = _
FLC
/
TRSEC
= 60 (A) / 121 (A) = 0,5
Where is

FLC
full load current (all loads current connected to T-01 transformer, see Key One Line Diagram
TP-9308Z-LC6-1-C1-7000)

TRSEC
transformer secondary current

TRSEC
= 121
) ( 480 3
) ( 100
) ( 3
) (

c '
'
' &
' $
(A)

FL4
= 5 , 0
4160 3
) ( 100
c
c
'
= 7 A

- Correction (deration) factor for underground installation is:
* Effect of soil thermal resistivity 1,2

-
DER
=
TOT
x 1,2 = 242,5 (A)

Voltage drop from Oil Field Substation to TZC-2:
V
D
= #
#
c c c ) sin cos ( 3
V
D
= 6 , 0 ) 53 , 0 112 , 0 83 , 0 0918 , 0 ( 5 , 242 3 c c c c c
V
D
= 34 V

Voltage at terminals of substation TZC-2
U
TZC-2
= U
A
V
D
= 4080 34 = 4046 V

Percentage voItage drop is
V (%) = 100 c

&
'
= 100
4080
34
c = 0,83 %

3.3 VoItage Drop CaIcuIation for the TZC- to TZC-3 CabIe Connection

Existing 5 kV Cable Parameters:

- Distance from SS Oil Substation to TZC-1 50 m
- XLPE Cable 5 kV 240 mm
2
(500 MCM)
- Resistance (90 C) R=0,0918 D/km (from Alcatel Canada Wire Catalogue)
- nductance (60 Hz) X=0,112 D/km (from Alcatel Canada Wire Catalogue)
- Maximum Current through the existing supply cable:


TOT
=
A
+
FL

TZC-2
= 120 + 82 - 10 = 192 A

TZC-2
TZC-2 transformer current = 10 A

- Correction (deration) factor for underground installation is:
* Effect of soil thermal resistivity 1,2

-
DER
=
TOT
x 1,2 = 230 (A)

Voltage drop from TZC-2 to TZC-3:
V
D
= #
#
c c c ) sin cos ( 3
V
D
= 05 , 0 ) 53 , 0 112 , 0 83 , 0 0918 , 0 ( 230 3 c c c c c
V
D
= 2,7 V

Voltage at terminals of substation TZC-3
V = U
TZC-2
V
D
= 4046 2,7 = 4043,3 V

Percentage voItage drop is
V (%) = 100 c

&
'
= 100
4080
7 , 2
c = 0,06 %


3.4 VoItage Drop CaIcuIation for TZC-3 to TZC-1 CabIe Connection

Existing 5 kV Cable Parameters:

- Distance from SS Oil Substation to TZC-1 100 m
- XLPE Cable 5 kV 240 mm
2
(500 MCM)
- Resistance (90 C) R=0,0918 D/km (from Alcatel Canada Wire Catalogue)
- nductance (60 Hz) X=0,112 D/km (from Alcatel Canada Wire Catalogue)
- Maximum Current through the existing supply cable:


TOT
=
A
+
FL

TZC-2

TZC-3
= 120 + 82 10 -10 = 182 A

TZC-2
TZC-2 transformer current = 10 A

TZC-3
TZC-3 transformer current = 10 A

- Correction (deration) factor for underground installation is:
* Effect of soil thermal resistivity 1,2

-
DER
=
TOT
x 1,2 = 218,4 (A)

Voltage drop from TZC-3 to TZC-1:
V
D
= #
#
c c c ) sin cos ( 3
V
D
= 1 , 0 ) 53 , 0 112 , 0 83 , 0 0918 , 0 ( 4 , 218 3 c c c c c
V
D
= 5,1 V

Voltage at terminals of substation TZC-1
U
TZC-1
= U
TZC-3
V
D
= 4043,3 5,1 = 4038,2 V

Percentage voItage drop is
V (%) = 100 c

&
'
= 100
4080
1 , 5
c = 0,1 %


3.5 VoItage Drop CaIcuIation for TZC-1 to RMU-1 CabIe Connection

Existing 5 kV Cable Parameters:

- Distance from SS Oil Substation to TZC-1 200 m
- XLPE Cable 5 kV 240 mm
2
(500 MCM)
- Resistance (90 C) R=0,0918 D/km (from Alcatel Canada Wire Catalogue)
- nductance (60 Hz) X=0,112 D/km (from Alcatel Canada Wire Catalogue)
- Maximum Current through the existing supply cable:


TOT
=
A
+
FL

TZC-2

TZC-3
-
TZC-1
= 120 + 82 10 10 10 = 172 A

TZC-2
TZC-2 transformer current = 10 A

TZC-3
TZC-3 transformer current = 10 A

TZC-1
TZC-1 transformer current = 10 A


- Correction (deration) factor for underground installation is:
* Effect of soil thermal resistivity 1,2

-
DER
=
TOT
x 1,2 = 206,4 (A)

Voltage drop from TZC-1 to RMU-1:
V
D
= #
#
c c c ) sin cos ( 3
V
D
= 2 , 0 ) 53 , 0 112 , 0 83 , 0 0918 , 0 ( 4 , 206 3 c c c c c
V
D
= 9,6 V

Voltage at terminals of substation RMU-1
U
RMU-1
= U
TZC-1
V
D
= 4038,2 9,6 = 4028,6 V

Percentage voItage drop is
V (%) = 100 c

&
'
= 100
4080
6 , 9
c = 0,3 %








3.4 VoItage Drop CaIcuIation for RMU-1 to MCC 4.16 kV CabIe Connection

Cable Parameters:

- Distance from RMU-1 to MCC 4.16 kV 4 m
- XLPE Cable 5 kV 240 mm
2
(500 MCM)
- Resistance (90 C) R=0,0918 D/km (from Alcatel Canada Wire Catalogue)
- nductance (60 Hz) X=0,112 D/km (from Alcatel Canada Wire Catalogue)
- Maximum Current through this cable:


TOT
=
FL1
= 43 A (from fire water pump Technical data)

- Correction (deration) factor for underground installation is:
* Effect of soil thermal resistivity 1,2
-
DER
=
TOT
x 1,2 = 51,6 A

Voltage drop from RMU-1 to MCC 4.16 kV:
V
D
= #
#
c c c ) sin cos ( 3
V
D
= 004 , 0 ) 53 , 0 112 , 0 83 , 0 0918 , 0 ( 6 , 51 3 c c c c c
V
D
= 0,05 V

Percentage voItage drop for cabIe connection from RMU-1 to MCC 4.16 kV is negIigibIe (short distance)!


3.5 VoItage Drop CaIcuIation for MCC 4.16 kV to Fire Motor Pump CabIe Connection

3.5.1 NormaI Running VoItage Drop CaIcuIation

Maximum permissible voltage drop for normal motor running conditions is 5 % (NEC 695.7) so minimum voltage
at the motor controller terminals have to be greater than 3952 V.

Cable Parameters:

- Distance from MCC 4.16 kV to MFW Pump 50 m
- XLPE Cable 5 kV 25 mm
2
(4 AWG)
- Resistance (75 C) R=0,95 D/km (from Alcatel Canada Wire Catalogue)
- nductance (60 Hz) X=0,141 D/km (from Alcatel Canada Wire Catalogue)
- Maximum Current through this cable:


TOT
=
FL1
= 43 A (from fire water pump Technical data)

- Correction (duration) factor for underground installation is:
* Ambient temperature (41-45 C) 0,82
* nstallation in tube 0,80
F
DER
= 0,82 x 0,80 = 0,66

-
DER
=
#
%%

=
66 , 0
43
= 65 A

Voltage drop from MCC 4.16 kV to Main Fire Motor Pump Controller:
V
D
= #
#
c c c ) sin cos ( 3
V
D
= 05 , 0 ) 53 , 0 141 , 0 83 , 0 95 , 0 ( 65 3 c c c c c
V
D
= 5 V

Voltage at Main Fire Pump Controller is
V = U
A
V
D
= 4036,45 5 = 4031,45 V > max tolerable voltage drop (5 %)


Percentage voItage drop for cabIe connection from MCC 4.16 kV to MFW Pump ControIIer is
V (%) = 100 c

&
'
= 100
45 , 4036
5
c = 0,1 %

3.5. Motor Starting VoItage Drop CaIcuIation

Maximum permissible voltage drop for motor starting conditions is 15 % (NEC 695.7) so minimum voltage at the
motor controller terminals have to be greater than 3536 V.

Cable Parameters:

- Distance from MCC 4.16 kV to MFW Pump 50 m
- XLPE Cable 5 kV 25 mm
2
(4 AWG)
- Resistance (75 C) R=0,95 D/km (from Alcatel Canada Wire Catalogue)
- nductance (60 Hz) X=0,141 D/km (from Alcatel Canada Wire Catalogue)
- Maximum Locked Rotor Current through this cable:


TOT
=
LRC
= 245,1 A (from fire water pump Technical data)

Voltage drop from MCC 4.16 kV to Main Fire Motor Pump Controller:
V
D
= #
#
c c c ) sin cos ( 3
V
D
= 05 , 0 ) 53 , 0 141 , 0 83 , 0 95 , 0 ( 1 , 245 3 c c c c c
V
D
= 10 V

Voltage at Main Fire Pump Controller is
V = U
A
V
D
= 4036,45 10 = 4026,45 V > 3536 V (max tolerable voltage drop 5 %) OK!


3.6 VoItage Drop CaIcuIation for RMU-1 to RMU- CabIe Connection

Cable Parameters:

- Distance from RMU-1 to RMU-2 4 m
- XLPE Cable 5 kV 240 mm
2
(500 MCM)
- Resistance (90 C) R=0,0918 D/km (from Alcatel Canada Wire Catalogue)
- nductance (60 Hz) X=0,112 D/km (from Alcatel Canada Wire Catalogue)

Distance from RMU-1 to RMU-2 is very short (4 m maximum) and voltage drop on this cable connection can be
negligible!


3.7 VoItage Drop CaIcuIation for RMU-1 to Power Transformer T-03 (50 kVA) CabIe Connection

Cable Parameters:

- Distance from RMU-1 to T-03 12 m
- XLPE Cable 5 kV 240 mm
2
(500 MCM)
- Resistance (90 C) R=0,0918 D/km (from Alcatel Canada Wire Catalogue)
- nductance (60 Hz) X=0,112 D/km (from Alcatel Canada Wire Catalogue)
- Maximum Current through this cable:


TOT
=
FL2
= 18 A (from fire water pump Technical data)

- Correction (deration) factor for underground installation is:
* Effect of three phase 0,87
* Effect of soil thermal resistivity 0,85
F
DER
= 0,87 x 0,85 = 0,74

-
DER
=
#
%%

=
74 , 0
18
= 24 A

Voltage drop from RMU-1 to T-03:
V
D
= #
#
c c c ) sin cos ( 3
V
D
= 012 , 0 ) 53 , 0 112 , 0 83 , 0 0918 , 0 ( 24 3 c c c c c
V
D
= 0,06 V

Percentage voItage drop for cabIe connection from RMU-1 to transformer T-03 is negIigibIe!

Voltage at transformer T-03 primary side is
V = U
A
V
D
= 4036,5 0,06 = 4036,44 V (3% voltage drop)

Also, voltage drop from RMU-1 to T-02 and from RMU-2 to T-01 is negligible because this cable connections
have short distances and secondary voltages for all three transformers will be less for 3 %.


3.8 Power Transformer T-0 and T-03 (50 kVA) VoItage Drop CaIcuIation

Transformer parameters (T-02 and T-03):
- Transformer power S = 250 kVA
- Primary voltage U
PRM
= 4,16 kV
- Secondary voltage U
SEC
= 480 V
- Transformer impedance Z = 5 %

Percentage Transformer Voltage Drop Calculation formula:

V
D
(%) =
) (
) ( 3
' $
' &
$
c c c


For one kilometre or longer pump location distances we can compensate voltage drop on this cable connections
with increasing voltage on the secondary side of transformers T-02 and T-03 (of load tap changer on + 5%).

480V + 5% = 504 V

n the paragraph 3.7 we saw that voltage drop on the primary side of transformers T-02 and T-03 is 3%, so
voltage on the secondary side of these transformers will also be less for 3%.

504 V 3% voltage drop U
SEC
= 489 V Secondary side voltage of transformers T-02 and T-03.

Full load current of transformers T-02 and T-03:

5 motors 20 HP have 5 x 28 A full load current (from NEC 430, table 430.130)

_
FLC
= 5 x 28 = 140 A


V
D
(%) =
) (
) ( 3
' $
' &
$
c c c
=
250
489 , 0 140 05 , 0 3 c c c
= 2,3 (%)

Transformer Voltage drop is:

V
D
=
100
()
$
& ' c
=
100
489 () 3 , 2 c
= 11 V

Voltage at the transformer secondary side is:

U
TOT
= U
SEC
- V
D
= 489 V 11 V = 478 V


3.9 Power Transformers T-0 and T-03 (50 kVA) to MCC- CabIe Connection VoItage Drop CaIcuIation

Cable Parameters:

- Distance from T-02 to MCC-2 10 m
- XLPE Cable 2x3x95 mm
2
(2 x 3/0 AWG)
- Resistance (90 C) R=0,498 D/km (from Alcatel Canada Wire Catalogue)
- nductance (60 Hz) X=0,184 D/km (from Alcatel Canada Wire Catalogue)
- cos = 0,82 sin = 0,53
- Maximum Current through this cable:


FLC
= 5 x 28 A = 140 A

- Deration factor = 0,82 (41 45 C)

DER
= 140 / 0,82 = 170 A

V
D
= #
#
c c c ) sin cos ( 3
V
D
= 01 , 0 ) 53 , 0 184 , 0 82 , 0 498 , 0 ( 170 3 c c c c c = 1,4 V

Voltage at MCC-2 is:
U
MCC-2
= U
TOT
V
D
= 478 1,45 =476,6 V

3.10 Power Transformer T-01 (100 kVA) VoItage Drop CaIcuIation

Transformer parameters (T-01):
- Transformer power S = 100 kVA
- Primary voltage U
PRM
= 4,16 kV
- Secondary voltage U
SEC
= 480 V
- Transformer impedance Z = 2,7 %

Percentage Transformer Voltage Drop Calculation formula:

V
D
(%) =
) (
) ( 3
' $
' &
$
c c c




n the paragraph 3.7 we saw that voltage drop on the primary side of transformers T-01 is 3%, so voltage on the
secondary side of these transformers will also be less for 3%.

480 V 3% voltage drop U
SEC
= 465,6 V Secondary side voltage of transformers T-01.

Full load current of transformers T-01:

_
FLC
= 60 A


V
D
(%) =
) (
) ( 3
' $
' &
$
c c c
=
100
4656 , 0 60 027 , 0 3 c c c
= 1,3 (%)

Transformer Voltage drop is:

V
D
=
100
()
$
& ' c
=
100
6 , 465 () 3 , 1 c
= 6 V

Voltage at the transformer secondary side is:

U
TOT
= U
SEC
- V
D
= 465,6 V 6 V = 459,6 V

3.11 Power Transformers T-01 (100 kVA) to MCC-1 CabIe Connection VoItage Drop CaIcuIation

Distance from transformer T-01 to MCC-1 is very short and voltage drop for this cable connection is
negligible.

3.1 MCC-1 to Fire Water Jockey Pumps CabIe Connection VoItage Drop CaIcuIation

Cable Parameters:

- Distance from MCC-1 to T-04 50 m
- XLPE Cable 6 mm
2
(10 AWG)
- cos = 0,82 sin = 0,53
- motor full load current 24 A (from NFPA 70, table 430.150 see attachment)
- motor locked rotor current 130 A (from NFPA 70, table 430.150 see attachment)
- voltage drop for cables cross section > 16 mm
2
can be calculated from below formula:
V
D
= # c c c 3
- direct current resistance at 75 C is 3,948 D/km for uncoated copper wire (NFPA 70, chapter 9, table 8 see
attachment 2). For our distance of 50 m direct current resistance is 0,2 D.

NormaI running FW Jockey Pump VoItage drop

V
D
= 1000 / 50 948 , 3 24 3 c c c = 8,3 V

Voltage at the Fire Water Jockey Pump is U
MCC-1
- V
D
= 459,6 8,3 = 451,3 V > 437 V (5 %)

Locked Rotor FW Jockey Pump VoItage drop


V
D
= 1000 / 50 948 , 3 130 3 c c c = 44 V < 69 V (max allowable voltage drop for motor starting - 15%)

3.13 MCC-1 to Indoor Transformer T-04 CabIe Connection VoItage Drop CaIcuIation

Cable Parameters:

- Distance from MCC-1 to T-04 10 m
- XLPE Cable 3x95 mm
2
(2 x 3/0 AWG)
- Resistance (90 C) R=0,249 D/km (from Alcatel Canada Wire Catalogue)
- nductance (60 Hz) X=0,092 D/km (from Alcatel Canada Wire Catalogue)
- cos = 0,82 sin = 0,53
- Maximum Current through this cable:

T-04 transformer full load current:

FL4
=
&
' $
c
c 3
) (


DF Demand Factor
DF = _
FLC
/
TRSEC
= 55 (A) / 111 (A) = 0,5
Where is

FLC
full load current (all loads current connected to T-04 transformer, see Lighting and Distribution
One Line Diagram TP-9398Z-LC6-1-C1-7004).

TRSEC
transformer secondary current

TRSEC
= 111
) ( 208 3
) ( 40
) ( 3
) (

c '
'
' &
' $
(A)

FL4
=
&
' $
c
c 3
) (
= 5 , 0
208 3
) ( 40
c
c
'
=55 A


- Deration factor = 0,82 (41 45 C)

DER
=
FL4
/ 0,82 = 67 A

V
D
= #
#
c c c ) sin cos ( 3
V
D
= 01 , 0 ) 53 , 0 092 , 0 82 , 0 249 , 0 ( 67 3 c c c c c = 0,29 V Voltage drop can be negligible.





Attachment 1 - Motors FuII Load Current TabIe