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t{V(\ Load Schedule - Open Electrical

Load Schedule
From Open Electrical
Contents
1 Introduction
1.1 Why do the calcu1ation?
1.2 When to do the calcu1ation?
2 Calculation Methodology
2.1 Step 1: Collect list of loads
2.2 Step 2: Collect l e ~ a l load paramrters
2.3 Step 3: Classify the loads
2.3.1 Voltage Level
2.3.2 Load duty
2.3.3 Load criticality
2.4 Step 4: Calculate consmred load
2.5 Step 5: Calcu1ate operating, peak and design loads
2.5.1 Operating Joad
2.5.2 Peak load
2.5.3 Design load
3 Worked Example
3 .1 Step 1 : Collect list of loads
3.2 Step 2: Collect l e ~ a l load paramrters
3.3 Step 3: Classify the loads
3.4 Step 4: Calcu1ate consmred load
3.5 Step 5: Calculate operating, peak and design loads
4 Operating Scenarios
5 Computer Software
6 What Next?
Introduction
The e l e ~ a l load schedule is an estimate of the inst:antaneous electrical loads operating in a filcility, in tenm of
active, reactive and apparent power (treasured in kW, kV AR and kVA respectively). The load schedule is usually
categorised by switchboard or occasxmally by sub-fu.cility I area.
Why do the calculation?
Preparing the load schedule is one of the earliest tasks that needs to be done as it is essentially a pre-requisite fur
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Load Schedule - Open El-ical
A mmiber of electrical load para.m:ters are necessary to construct the load schedule:
Rated power is the full load or nameplate rating of the load and represents the maxinrum continuous
power output of the load. For m>tor loads, the rated power corresponds to the standard m>tor size
(e.g. l lkW, 37kW, 75kW, etc). For load item; that contain sub-loads (e.g. distribution boards,
package equipment, etc), the rated power is typicallythe maxinrumpower output of the item(i.e. with
all its sub-loads in service).
Absorbed power is the expected power that will be drawn by the load. Most loads will not operate
at its rated capacity, but at a lower point. For example, absorbed m>tor loads are based on the
mechanical power input to the shaft of the driven equipment at its duty point. The m>tor is typically
sized so that the rated capacity of the m>tor exceeds the expected absorbed load by some
conservative design margin. Where infurmation regarding the absorbed loads is not available, then a
load fuctor ofbetween 0.8 and 0.9 is normally applied.
Power factor of the load is necessary to determine the reactive components of the load schedule.
Normally the load power fuctor at full load is used, but the power fuctor at the duty point can also be
used fur increased accuracy. Where power fuctors are not readily available, then estimates can be
used (typically 0.85 fur m>tor loads >7.5kW, 1.0 fur heater loads and 0.8 fur all other loads).
Efficiency accounts fur the losses incurred when converting electrical energy to mechanical energy
(or whatever type of energy the load outputs). Some of the electrical power drawn by the load is lost,
usually in the furm ofheat to the ambient environment. Where infurmation regarding efficiencies is not
available, then estimates ofbetween 0.8 and 1 can be used (typically 0.85 or 0.9 is used when
efficiencies are unknown).
Step 3: Classify the loads
Once the loads have been identified, they need to be classified accordingly:
Voltage Level
What voltage level and which switchboard should the load be located? Large loads may need to be on MV or HV
switchboards depending on the size of the load and how many voltage levels are available. Typically, loads
<150kWtend to be on the LY system(400V - 690V), loads between 150kW and lOMW tend to be on an
intermediate MV system(3.3kV - 6.6kV) where available and loads >lOMW are usually on the HV distribution
system (1 lkV - 33kV). Some consideration should also be made fur grouping the loads on a switchboard in terms
of sub-fucilities, areas or sub-system; (e.g. a switchboard fur the compression train sub-system or the drying area).
Load duty
Loads are classified according to their duty as either continuous, intermittent and standby loads:
1) Continuous loads are those that normally operate continuously over a 24 hour period, e.g. process loads,
control system>, lighting and small power distribution boards, UPS system;, etc
2) lntennittent loads that only operate a fraction ofa 24 hour period, e.g. intermittent pumps and process
loads, automatic doors and gates, etc
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Lmd &:had!Je - Open Electrical
3) Standby Joads are those that are on standby or rarely operate under nonm1 conditi>m, e.g. standby
loads, enEgency systems, etc
Note that fur redundant loads (e.g. 2 x I 00% duty I standby tmtors ), one is usually c1assified as contirmom and the
other classified as stmlby. This if purely fur the purposes of the had schedule and does not re.ftect the actual
operating conditions of the Joads, ie. both redmidant Joads will be equally used even though one is c1assified as a
standby had.
Load criticality
Loads are typically classified as either normal, essential and critical:
1) N onml loads are 1hose that nm under normal operating cotxlitions, e.g. main process loads, normal
lighting and small power, ordinary office and workshop k>ads, etc
2) Essential bads are those necessary under eimrgency conditi>ns, when the main power supply is
dticonnected and the system is being supported by an eimrgency generator, e.g. em:rgency lighting, key
process bads that operate dming conditions, fire and sarety system;, etc
3) Critical are 1hose critical fur the operation of safety systetm and fur mcilitating or assisting evacuation
ftom the plant, and wouki mnmlly be supplied from a UPS or battery system, e.g. safuty-critical slmtdown
systooE, escape 1ighting, etc
Step 4: Calculate consumed load
The consl.llDOO k>ad is the quantity of electrical power that the Joad is expected to consurm. For each had,
cakulate the comuin:d active and reactive hading, derived as fullows:
.?,, = P abs
T/
Qi = Pi J

- 1
Where Pi is the comuin:d active Joad (kW)
Q l is the cOffilDD:d reactive had (kV Ar)
P abs is the absorbed had (kW)
T/ is tre load effcimcy (pu)
cos is the Joad power filctor (pu)
Notice that the loads have been categorised into three cohmn depending on their load duty ( continuom,
inte.tmittent or standby). This is done in order to mike it v6ually easier to see the had duty and Jmre importantly,
to :rmke it easier to smn the bads according to their duty (e.g. smn of all continuom loads), which is necessary to
cakulate the operatin& peak and design Joads.
Step S: Calculate operating, peak and design loads
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Many organisations I clicm have their own distinct Jrethod fur ca1culating operating, peak and design bads, but a
generic tm1hod is presented as :fi>Dows:
Operating load
The operating Joad is the expected had during oormal operation. The operating Joad is cabJlated as futbws:
Where O L is the operating Joad (kW or kV Ar)
Peak load
L Le is the sum of an continuous loads (kW or kV Ar)
L Li is the sum of an intermittent :loads (kW or kV Ar)
The peak Joad is the expected maximum. :load during nonnal operafun Peak :loading is typX:ally inftequent and of
short duratim, occurring when standby bads are operated (e.g. fur changeover of redundant rmchines, testing of
sarety equipimnt, etc). The peak Joad is cakuJated as the 1arger of either:
or
Where p L is the peak Joad (kW or kV Ar)
L Le is the sum of an continuous Joads (kW or kV Ar)
L Li is the sum of an intermittent loads (kW or kV Ar)
L L s is the sum of an standby Joads (kW or kV Ar)
L s:max is the 1argest standbyJoad (kW orkVAr)
Design load
The design Joad is the had to be used tor the design :IDr equipmmt sizing, eJectri:al studies, etc. The design load is
generically cakuJated as the larger of either:
DL = 1.1 X OL + O.l X L Ls
or
DL = 1.1 x OL + Ls.max
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Where D L is the design Joad (kW or kV Ar)
O L is the operating had (kW or kV Ar)
L L
5
is the sum of all standby Joads (kW or kV Ar)
L s:max. is the largest standby had (kW orkVAr)
'The design load includes a margin fur any errors in load estimatXm, had growth or the addition of unfureseen loads
that may appear after the design phase. The Joad scheduJe is thus m>re comervative and robust to errors. On the
other hand however, equipmn is often over-siled as a resuh. S o ~ the design Joad is not caku1ated and the
peak Joad is used fur design purposes.
Worked Example
Step 1: Collect list of loads
Conmer a small mcitity with the fullowing loads identified:
2 x I 00% vapour recovery cmquessors (process)
2 x I 00% recirculation pumps (process)
I x I 00% sump pwq> (process)
2 x 50% :firewater pwq>s (safety)
Ix 100%INAC mit(HVAC)
I x I 00% AC UPS system (electrical)
I x Nonml lighting distribution board (electrical)
I x Essential lighting distribution board ( e1ectrical)
Step 2: Collect electrical load parameters
The fullowing electrical load panum:ers were co11ecred fur the hads identified in Step 1 :
Load Description Abs.Load Rated Load PF Etl.
Vapour recovery corrpressor A 750kW 800kW 0.87 0.95
Vapour recovery corq>ressor B 750kW 800kW 0.87 0.95
Recirculation pump A 3lkW 37kW 0.83 0.86
Recirculation pump B 3lkW 37kW 0.83 0.86
SUJI> pump 9kW llkW 0.81 0.83
Firewater pump A 65kW 75kW 0.88 0.88
Firewater pump B
65kW 75kW 0.88 0.88
INACunit 80kW 90kW 0.85 0.9
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t{V(\ Load Schedule - Open Electrical
AC UPS System 9kW 12kW 0.85 0.9
Normal lighting distribution board ?kW lOkW 0.8 0.9
Essential ligl t i1 ig distribution board 4kW 5kW 0.8 0.9
Step 3: Classify the loads
Suppose we have two voltage leve1s, 6.6kV and 415V. The loads can be classified as fullows:
Load Description Rated Load Vohage Duty Criticality
Vapm.ll' recovery compressor A 800kW 6.6kV Continuous Nonnal
Vapour recovery compressor B 800kW 6.6kV Standby Nonnal
Recirculation pump A 37kW 415V Continuous Nonnal
Recirculation pump B 37kW 415V Standby Nonnal
Sump pump llkW 415V Intermittent Nonnal
Firewater pump A 75kW 415V Standby Essential
Firewater pump B 75kW 415V Standby Essential
HVACunit 90kW 415V Continuous Nonnal
AC UPS System 12kW 415V Continuous Critical
Normal lighting distribution board lOkW 415V Continuous Nonnal
Essential lighting distribution board SkW 415V Continuous Essential
Step 4: Calculate consumed load
Calculating the loads fur each of the loads in this example gives:
Continuous lntennittent Standby
Load Description
Abs
PF Eff.
Load
Q Q Q
P(kW)
(kVAr)
P(kW)
(kVAr)
P(kW)
(kVAr)
Vapour recovery
750kW 0.87 0.95 789.5 447.4 - - - -
compressor A
Vapour recovery
750kW 0.87 0.95 789.5 447.4
- - - -
compressor B
Recirculation pump
31kW 0.83 0.86 36.0 24.2
A
- - - -
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~ . t{V(\ Load Schedule - Open Electrical
Recirculation pmnp
3lkW 0.83 0.86 36.0 24.2
- - - -
B
Smnppmnp 9kW 0.81 0.83 - - 10.8 7.9 - -
Firewater pmnp A 65kW 0.88 0.88
- - - -
73.9 39.9
Firewater pmnp B 65kW 0.88 0.88 - - - - 73.9 39.9
HVACtmit 80kW 0.85 0.9 88.9 55.1 - - - -
AC UPS System 9kW 0.85 0.9 10.0 6.2 - - - -
N omral Jighting
7kW 0.8 0.9 7.8 5.8 - - - -
distribution board
Essential lighting
4kW
distribution board
0.8 0.9 4.4 3.3
- - - -
SUM TOTAL 936.6 542.0 10.8 7.9 973.3 551.4
Step 5: Calculate operating, peak and design loads
The operating, peak and design Joads are ca1cu1ated as fuDows:
P(kW) Q(kW)
Smnof continuous loads 936.6 542.0
50% x Smn of intennittent loads 5.4 4.0
10% x Smn of standby loads 97.3 55.1
Largest standby load 789.5 447.4
Operating load 942 546.0
Peak load 1,731.5 993.4
Design load 1,825.7 1,047.9
Normally you would separate the loads by switchboard and calculate operating, peak and design loads fur each
switchboard and one fur the overall system However fur the sake of simplicity, the loads in this example are all
hnnped together and only one set of operating, peak and design loads are calculated.
Operating Scenarios
It may be necessary to co:ns1ruct load schedules fur di:fterent operating scenarios. For example, in order to s ~ an
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Load Schedule - Open El-ical
eirergency diesel generator, it would be necessary to construct a load schedule fur eirergency scenarios. The
classification of the loads by criticality will help in constructing ahemative scenarios, especially those that use
ahernative power sources.
Computer Software
In the past, the load schedule has typically been done manually by hand or with the help of an Excel spreadsheet.
However, this type of calculation is extremely well-suited fur database driven software packages (such as
Smartplant Electrical (ht1p:l/www.intergraph.com'products/ppm'smartplant/electricaVderauh.aspx) ), especially fur
very large projects. For smaller projects, it may be fur easier to simply perfurm this calculation manually.
What Next?
The electrical load schedule is the basis fur the sizing of tmst major electrical equipmmt, from generators to
switchgear to transfurmers. Using the load schedule, major equipment sizing can be started, as well as the power
system studies. A preliminary load schedule will also indicate if there will be problems with available power supply I
generation, and whether ahemative power sources or even process designs will need to be investigated.
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This page was lasttmdified on 7 April2013, at 09:28.
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