Module 1: Cable Sizing Fundamentals — Standards, Principles, and the Design Process
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Foundations of Cable Sizing
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Module 1 Learning Outcomes
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Why Cable Sizing Matters
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The 4 Critical Parameters
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LV vs MV — Voltage Levels in Practice
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Copper vs Aluminium — Choosing the Right Conductor
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Cable Insulation Types
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The Standards Behind the Calculator
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Reading the Calculator — Colour Coding System
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Short-Circuit Withstand Constants — Memorise These
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Your Calculator — 6 Sheets, One Workflow
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Module 1 Complete
Module 2: SANS 10142 and IEC 60364 — What Every Engineer Must Know
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Inside the Excel Calculator
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Module 2 Learning Outcomes
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The Calculator: 8 Sections — A Through H
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Project Information
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Load Data — The Inputs That Drive Everything
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IFL and Istart — The Two Currents
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Cable Type Selection
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Derating Factors
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Cable Selection — Choose Size
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Voltage Drop Check
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Short-Circuit / Fault Current Check
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Results Summary — The Traffic-Light View
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The Pre-Loaded FAIL Scenario — Why It Fails
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The PRINT REPORT — Your Professional Deliverable
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Module 2 Formula Reference Card
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Module 2 Complete
Module 3: Current-Carrying Capacity — Tables, Grouping, and Installation Methods
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Step-by-Step Cable Sizing Workflow
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LEARNING OUTCOMES
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The 8-Step Cable Sizing Workflow
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Define Load Requirements
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Steps 2 & 3 — Set the Limits, Choose the Cable
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STEP 4 — Determine Derating Factors
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STEP 5 — Select Cable Size from Tables
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Steps 6 & 7 — Voltage Drop & Short-Circuit Checks
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STEP 8 — Compliance Review & Iteration
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WORKED EXAMPLE — 75 kW Motor Cable
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Engineering Judgement & Documentation
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Module 3 Summary
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What's Next in the Masterclass
Module 4: Derating Factors — Ambient Temperature, Grouping, Thermal Insulation
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Where Most Engineers Make Costly Mistakes
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Module 4 Learning Outcomes
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Why Voltage Drop Matters — The Real-World Consequences
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THE FORMULA DISSECTED
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SANS 10142-1 — Voltage Drop Limits (Clause 5.3)
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THE FAIL SCENARIO
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Sensitivity Analysis — What Changes VD and By How Much?
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Upsize the Cable
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Solution 2: Add Parallel Cables (N > 1)
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Reduce the Cable Run — And the Three-Solution Comparison
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Starting Voltage Drop — The WARNING You Must Understand
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Verify the Calculator — Do the Maths by Hand
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The 6 Most Common Voltage Drop Mistakes
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QUICK ESTIMATION TOOL
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Real-World Scenarios — Where VD Failures Hurt Most
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Module 4 Complete
Module 5: Voltage Drop Calculations — Method, Formula, and Acceptable Limits
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Short-Circuit & Thermal Withstand
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What You Will Be Able to Do
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What Happens to a Cable During a Fault?
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PROSPECTIVE FAULT CURRENT
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WORKED EXAMPLE
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The K-Factor — What It Represents
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THERMAL WITHSTAND FORMULA
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WORKED EXAMPLE
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Effect of Clearing Time on Cable Withstand
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Using the Calculator: Section G Fault Current Check
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MV CABLE TABLES
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Three Mistakes That Cause FAIL Results
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What To Do Now — Hands-On Practice
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MODULE 5 SUMMARY
Module 6: Motor Cable Sizing — Starting Current, Protection, and Coordination
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Installation Methods & Derating
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What You'll Learn in Module 6
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Why Cables Are Derated
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The Six Derating Factors
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Solar Radiation — South African Context
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Cable Grouping — The Hidden Derating
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Combining Factors: F_total and Ir
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Calculator Section D — Derating Inputs
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LV Derating Quick Reference
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Practical Exercise — Your Turn
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Module 6 — Key Takeaways & Assessment
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Module 6 Complete
Module 7: Professional Cable Schedules and Documentation
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Real-World Case Studies
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Module Purpose
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Learning Outcomes
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The 5 Case Studies at a Glance
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Case Study 1 — Industrial Motor
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Case Study 2 — Mining Long Run
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Case Study 3 — MV Substation Feeder
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Case Study 4 — Petrochemical Harsh Environment
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Case Study 5 — Aluminium Cable Sizing
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Calculator Focus — Which Check Controls the Cable?
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Practical Engineering Activities
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Resources & Downloadable Tools
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MODULE 7 — KEY TAKEAWAYS
Module 8: Worked Examples — 4 Complete Projects from Load List to Final Schedule
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Common Mistakes & Design Pitfalls
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Module Purpose
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Learning Outcomes
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The 8 Mistakes at a Glance
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Mistake 1 — Ignoring Derating Factors
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Mistake 2 — Wrong K-Factor for SC Withstand
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Mistake 3 — Misreading Starting VD WARNING as a FAIL
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Mistakes 4 & 5 — Over-Design vs Under-Design
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Mistakes 6, 7 & 8 — Three Quick But Costly Errors
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Calculator Focus — Reading Section H Correctly
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Deep Dive — K-Factor Error Impact on SC Withstand
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10-Point Design Review Checklist
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MODULE 8 — KEY TAKEAWAYS
MODULE 9: From Calculation to Design Documentation
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From Calculation to Design Documentation
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What This Module Is About
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Learning Outcomes
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The 6 Sections of a Cable Sizing Report
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PRINT REPORT Sheet Walkthrough
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The SANS Compliance Statement
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Revision Control for Engineering Calculations
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Engineering Justification Statements
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Registered Engineer Sign-Off
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Transmittal & Submission Process
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Document Control — File Naming & Version History
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Case Study: Mining Calculation Package
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Key Takeaways — Module 9
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MODULE 9 COMPLETE
MODULE 10: Optimising Cost, Quick Estimation & Red Flags
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Optimising Cost, Quick Estimation & Red Flags
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Learning Outcomes
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Cable Cost Optimisation
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Copper vs Aluminium — When Does Al Make Sense?
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Parallel Cable Economics
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Rules of Thumb for Early Project Stages
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MV Cable Optimisation
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Cable Sizing Red Flags — Know When to Stop and Review
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AI & Automation in Cable Sizing
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Optimisation in Action — Calculator Exercise
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Key Takeaways
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What's Next — Capstone Project
MODULE 11: Full Industrial Panel Cable Sizing Exercise
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Full Industrial Panel Cable Sizing Exercise
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What This Module Is — and Is Not
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The Scenario: Highveld Mining Support Facility
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Every Cable Gets Three Checks
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Cable 01: 75 kW VSD Motor
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Cable 01: Key Calculations Walkthrough
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Cable 02: 22 kW DOL Motor — Buried Direct
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Cable 03: 15 kW Lighting Feeder — Conduit/Duct
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Cable 04: 100 kVA Sub-Feeder — 3 Cables Grouped
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Derating Factors: Quick Reference for This Project
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Assembling Your Calculation Package
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How Your Capstone Will Be Reviewed
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Five Common Capstone Mistakes
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Indicative Results — Use to Check Your Work
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You've Completed the Capstone Project
COURSE DOWNLOADS
