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LoadScheduleOpenElectrical
LoadSchedule
FromOpenElectrical
Contents
1Introduction
1.1Whydothecalculation?
1.2Whentodothecalculation?
2CalculationMethodology
2.1Step1:Collectlistofloads
2.2Step2:Collectelectricalloadparameters
2.3Step3:Classifytheloads
2.3.1VoltageLevel
2.3.2Loadduty
2.3.3Loadcriticality
2.4Step4:Calculateconsumedload
2.5Step5:Calculateoperating,peakanddesignloads
2.5.1Operatingload
2.5.2Peakload
2.5.3Designload
3WorkedExample
3.1Step1:Collectlistofloads
3.2Step2:Collectelectricalloadparameters
3.3Step3:Classifytheloads
3.4Step4:Calculateconsumedload
3.5Step5:Calculateoperating,peakanddesignloads
4OperatingScenarios
5ComputerSoftware
6WhatNext?
Introduction
Theelectricalloadscheduleisanestimateoftheinstantaneouselectricalloads
operatinginafacility,intermsofactive,reactiveandapparentpower(measuredin
kW,kVARandkVArespectively).Theloadscheduleisusuallycategorisedby
switchboardoroccasionallybysubfacility/area.
Whydothecalculation?
Preparingtheloadscheduleisoneoftheearliesttasksthatneedstobedoneasitis
essentiallyaprerequisiteforsomeofthekeyelectricaldesignactivities(suchas
equipmentsizingandpowersystemstudies).
Whentodothecalculation?
Figure1.Exampleofanelectricalloadschedule
Theelectricalloadschedulecantypicallybestartedwithapreliminarykeysingle
linediagram(oratleastanideaofthemainvoltagelevelsinthesystem)andanypreliminarydetailsofprocess/building/facilityloads.Itis
recommendedthattheloadscheduleisstartedassoonaspracticallypossible.
CalculationMethodology
Therearenostandardsgoverningloadschedulesandthereforethiscalculationisbasedongenerallyacceptedindustrypractice.Thefollowing
methodologyassumesthattheloadscheduleisbeingcreatedforthefirsttimeandisalsobiasedtowardsindustrialplants.Thebasicstepsforcreatinga
loadscheduleare:
Step1:Collectalistoftheexpectedelectricalloadsinthefacility
Step2:Foreachload,collecttheelectricalparameters,e.g.nominal/absorbedratings,powerfactor,efficiency,etc
Step3:Classifyeachoftheloadsintermsofswitchboardlocation,loaddutyandloadcriticality
Step4:Foreachload,calculatetheexpectedconsumedload
Step5:Foreachswitchboardandtheoverallsystem,calculateoperating,peakanddesignload
Step1:Collectlistofloads
Thefirststepistogatheralistofalltheelectricalloadsthatwillbesuppliedbythepowersystemaffectedbytheloadschedule.Therearegenerallytwo
typesofloadsthatneedtobecollected:
Processloadsaretheloadsthataredirectlyrelevanttothefacility.Infactoriesandindustrialplants,processloadsarethemotors,heaters,
compressors,conveyors,etcthatformthemainbusinessoftheplant.ProcessloadscannormallybefoundoneitherMechanicalEquipment
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ListsorProcessandInstrumentationDiagrams(P&ID's).
Nonprocessloadsaretheauxiliaryloadsthatarenecessarytorunthefacility,e.g.lighting,HVAC,utilitysystems(powerandwater),
DCS/PLCcontrolsystems,firesafetysystems,etc.Theseloadsareusuallytakenfromanumberofsources,forexampleHVACengineers,
instruments,telecomsandcontrolsystemsengineers,safetyengineers,etc.Someloadssuchaslighting,UPS,powergenerationauxiliaries,
etcneedtobeestimatedbytheelectricalengineer.
Step2:Collectelectricalloadparameters
Anumberofelectricalloadparametersarenecessarytoconstructtheloadschedule:
Ratedpoweristhefullloadornameplateratingoftheloadandrepresentsthemaximumcontinuouspoweroutputoftheload.Formotor
loads,theratedpowercorrespondstothestandardmotorsize(e.g.11kW,37kW,75kW,etc).Forloaditemsthatcontainsubloads(e.g.
distributionboards,packageequipment,etc),theratedpoweristypicallythemaximumpoweroutputoftheitem(i.e.withallitssubloads
inservice).
Absorbedpoweristheexpectedpowerthatwillbedrawnbytheload.Mostloadswillnotoperateatitsratedcapacity,butatalowerpoint.
Forexample,absorbedmotorloadsarebasedonthemechanicalpowerinputtotheshaftofthedrivenequipmentatitsdutypoint.The
motoristypicallysizedsothattheratedcapacityofthemotorexceedstheexpectedabsorbedloadbysomeconservativedesignmargin.
Whereinformationregardingtheabsorbedloadsisnotavailable,thenaloadfactorofbetween0.8and0.9isnormallyapplied.
Powerfactoroftheloadisnecessarytodeterminethereactivecomponentsoftheloadschedule.Normallytheloadpowerfactoratfullload
isused,butthepowerfactoratthedutypointcanalsobeusedforincreasedaccuracy.Wherepowerfactorsarenotreadilyavailable,then
estimatescanbeused(typically0.85formotorloads>7.5kW,1.0forheaterloadsand0.8forallotherloads).
Efficiencyaccountsforthelossesincurredwhenconvertingelectricalenergytomechanicalenergy(orwhatevertypeofenergytheload
outputs).Someoftheelectricalpowerdrawnbytheloadislost,usuallyintheformofheattotheambientenvironment.Whereinformation
regardingefficienciesisnotavailable,thenestimatesofbetween0.8and1canbeused(typically0.85or0.9isusedwhenefficienciesare
unknown).
Step3:Classifytheloads
Oncetheloadshavebeenidentified,theyneedtobeclassifiedaccordingly:
VoltageLevel
Whatvoltagelevelandwhichswitchboardshouldtheloadbelocated?LargeloadsmayneedtobeonMVorHVswitchboardsdependingonthesizeof
theloadandhowmanyvoltagelevelsareavailable.Typically,loads<150kWtendtobeontheLVsystem(400V690V),loadsbetween150kWand
10MWtendtobeonanintermediateMVsystem(3.3kV6.6kV)whereavailableandloads>10MWareusuallyontheHVdistributionsystem(11kV
33kV).Someconsiderationshouldalsobemadeforgroupingtheloadsonaswitchboardintermsofsubfacilities,areasorsubsystems(e.g.a
switchboardforthecompressiontrainsubsystemorthedryingarea).
Loadduty
Loadsareclassifiedaccordingtotheirdutyaseithercontinuous,intermittentandstandbyloads:
1)Continuousloadsarethosethatnormallyoperatecontinuouslyovera24hourperiod,e.g.processloads,controlsystems,lightingandsmall
powerdistributionboards,UPSsystems,etc
2)Intermittentloadsthatonlyoperateafractionofa24hourperiod,e.g.intermittentpumpsandprocessloads,automaticdoorsandgates,etc
3)Standbyloadsarethosethatareonstandbyorrarelyoperateundernormalconditions,e.g.standbyloads,emergencysystems,etc
Notethatforredundantloads(e.g.2x100%duty/standbymotors),oneisusuallyclassifiedascontinuousandtheotherclassifiedasstandby.Thisif
purelyforthepurposesoftheloadscheduleanddoesnotreflecttheactualoperatingconditionsoftheloads,i.e.bothredundantloadswillbeequally
usedeventhoughoneisclassifiedasastandbyload.
Loadcriticality
Loadsaretypicallyclassifiedaseithernormal,essentialandcritical:
1)Normalloadsarethosethatrunundernormaloperatingconditions,e.g.mainprocessloads,normallightingandsmallpower,ordinaryoffice
andworkshoploads,etc
2)Essentialloadsarethosenecessaryunderemergencyconditions,whenthemainpowersupplyisdisconnectedandthesystemisbeing
supportedbyanemergencygenerator,e.g.emergencylighting,keyprocessloadsthatoperateduringemergencyconditions,fireandsafety
systems,etc
3)Criticalarethosecriticalfortheoperationofsafetysystemsandforfacilitatingorassistingevacuationfromtheplant,andwouldnormallybe
suppliedfromaUPSorbatterysystem,e.g.safetycriticalshutdownsystems,escapelighting,etc
Step4:Calculateconsumedload
Theconsumedloadisthequantityofelectricalpowerthattheloadisexpectedtoconsume.Foreachload,calculatetheconsumedactiveandreactive
loading,derivedasfollows:
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Where
LoadScheduleOpenElectrical
istheconsumedactiveload(kW)
istheconsumedreactiveload(kVAr)
istheabsorbedload(kW)
istheloadefficiency(pu)
istheloadpowerfactor(pu)
Noticethattheloadshavebeencategorisedintothreecolumnsdependingontheirloadduty(continuous,intermittentorstandby).Thisisdoneinorder
tomakeitvisuallyeasiertoseetheloaddutyandmoreimportantly,tomakeiteasiertosumtheloadsaccordingtotheirduty(e.g.sumofallcontinuous
loads),whichisnecessarytocalculatetheoperating,peakanddesignloads.
Step5:Calculateoperating,peakanddesignloads
Manyorganisations/clientshavetheirowndistinctmethodforcalculatingoperating,peakanddesignloads,butagenericmethodispresentedas
follows:
Operatingload
Theoperatingloadistheexpectedloadduringnormaloperation.Theoperatingloadiscalculatedasfollows:
Where
istheoperatingload(kWorkVAr)
isthesumofallcontinuousloads(kWorkVAr)
isthesumofallintermittentloads(kWorkVAr)
Peakload
Thepeakloadistheexpectedmaximumloadduringnormaloperation.Peakloadingistypicallyinfrequentandofshortduration,occurringwhen
standbyloadsareoperated(e.g.forchangeoverofredundantmachines,testingofsafetyequipment,etc).Thepeakloadiscalculatedasthelargerof
either:
or
Where
isthepeakload(kWorkVAr)
isthesumofallcontinuousloads(kWorkVAr)
isthesumofallintermittentloads(kWorkVAr)
isthesumofallstandbyloads(kWorkVAr)
isthelargeststandbyload(kWorkVAr)
Designload
Thedesignloadistheloadtobeusedforthedesignforequipmentsizing,electricalstudies,etc.Thedesignloadisgenericallycalculatedasthelargerof
either:
or
Where
isthedesignload(kWorkVAr)
istheoperatingload(kWorkVAr)
isthesumofallstandbyloads(kWorkVAr)
isthelargeststandbyload(kWorkVAr)
Thedesignloadincludesamarginforanyerrorsinloadestimation,loadgrowthortheadditionofunforeseenloadsthatmayappearafterthedesign
phase.Theloadscheduleisthusmoreconservativeandrobusttoerrors.Ontheotherhandhowever,equipmentisoftenoversizedasaresult.
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Sometimesthedesignloadisnotcalculatedandthepeakloadisusedfordesignpurposes.
WorkedExample
Step1:Collectlistofloads
Considerasmallfacilitywiththefollowingloadsidentified:
2x100%vapourrecoverycompressors(process)
2x100%recirculationpumps(process)
1x100%sumppump(process)
2x50%firewaterpumps(safety)
1x100%HVACunit(HVAC)
1x100%ACUPSsystem(electrical)
1xNormallightingdistributionboard(electrical)
1xEssentiallightingdistributionboard(electrical)
Step2:Collectelectricalloadparameters
ThefollowingelectricalloadparameterswerecollectedfortheloadsidentifiedinStep1:
LoadDescription
Abs.Load
Rated
Load
PF
Eff.
VapourrecoverycompressorA
750kW
800kW
0.87
0.95
VapourrecoverycompressorB
750kW
800kW
0.87
0.95
RecirculationpumpA
31kW
37kW
0.83
0.86
RecirculationpumpB
31kW
37kW
0.83
0.86
Sumppump
9kW
11kW
0.81
0.83
FirewaterpumpA
65kW
75kW
0.88
0.88
FirewaterpumpB
65kW
75kW
0.88
0.88
HVACunit
80kW
90kW
0.85
0.9
ACUPSSystem
9kW
12kW
0.85
0.9
Normallightingdistributionboard
7kW
10kW
0.8
0.9
Essentiallightingdistributionboard
4kW
5kW
0.8
0.9
Step3:Classifytheloads
Supposewehavetwovoltagelevels,6.6kVand415V.Theloadscanbeclassifiedasfollows:
LoadDescription
Rated
Load
Voltage
Duty
Criticality
VapourrecoverycompressorA
800kW
6.6kV
Continuous
Normal
VapourrecoverycompressorB
800kW
6.6kV
Standby
Normal
RecirculationpumpA
37kW
415V
Continuous
Normal
RecirculationpumpB
37kW
415V
Standby
Normal
Sumppump
11kW
415V
Intermittent
Normal
FirewaterpumpA
75kW
415V
Standby
Essential
FirewaterpumpB
75kW
415V
Standby
Essential
HVACunit
90kW
415V
Continuous
Normal
ACUPSSystem
12kW
415V
Continuous
Critical
Normallightingdistributionboard
10kW
415V
Continuous
Normal
Essentiallightingdistributionboard
5kW
415V
Continuous
Essential
Step4:Calculateconsumedload
Calculatingtheconsumedloadsforeachoftheloadsinthisexamplegives:
LoadDescription
AbsLoad
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PF
Eff.
Continuous
P(kW)
Q(kVAr)
Intermittent
P(kW)
Q(kVAr)
Standby
P(kW)
Q(kVAr)
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VapourrecoverycompressorA
750kW
0.87
0.95
789.5
447.4
VapourrecoverycompressorB
750kW
0.87
0.95
789.5
447.4
RecirculationpumpA
31kW
0.83
0.86
36.0
24.2
RecirculationpumpB
31kW
0.83
0.86
36.0
24.2
Sumppump
9kW
0.81
0.83
10.8
7.9
FirewaterpumpA
65kW
0.88
0.88
73.9
39.9
FirewaterpumpB
65kW
0.88
0.88
73.9
39.9
HVACunit
80kW
0.85
0.9
88.9
55.1
ACUPSSystem
9kW
0.85
0.9
10.0
6.2
Normallightingdistribution
board
7kW
0.8
0.9
7.8
5.8
Essentiallightingdistribution
board
4kW
0.8
0.9
4.4
3.3
936.6
542.0
10.8
7.9
973.3
551.4
SUMTOTAL
Step5:Calculateoperating,peakanddesignloads
Theoperating,peakanddesignloadsarecalculatedasfollows:
P(kW)
Q(kW)
Sumofcontinuousloads
936.6
542.0
50%xSumofintermittentloads
5.4
4.0
10%xSumofstandbyloads
97.3
55.1
Largeststandbyload
789.5
447.4
Operatingload
942
546.0
Peakload
1,731.5
993.4
Designload
1,825.7
1,047.9
Normallyyouwouldseparatetheloadsbyswitchboardandcalculateoperating,peakanddesignloadsforeachswitchboardandonefortheoverall
system.Howeverforthesakeofsimplicity,theloadsinthisexamplearealllumpedtogetherandonlyonesetofoperating,peakanddesignloadsare
calculated.
OperatingScenarios
Itmaybenecessarytoconstructloadschedulesfordifferentoperatingscenarios.Forexample,inordertosizeanemergencydieselgenerator,itwould
benecessarytoconstructaloadscheduleforemergencyscenarios.Theclassificationoftheloadsbycriticalitywillhelpinconstructingalternative
scenarios,especiallythosethatusealternativepowersources.
ComputerSoftware
Inthepast,theloadschedulehastypicallybeendonemanuallybyhandorwiththehelpofanExcelspreadsheet.However,thistypeofcalculationis
extremelywellsuitedfordatabasedrivensoftwarepackages(suchasSmartplantElectrical
(http://www.intergraph.com/products/ppm/smartplant/electrical/default.aspx)),especiallyforverylargeprojects.Forsmallerprojects,itmaybefar
easiertosimplyperformthiscalculationmanually.
WhatNext?
Theelectricalloadscheduleisthebasisforthesizingofmostmajorelectricalequipment,fromgeneratorstoswitchgeartotransformers.Usingtheload
schedule,majorequipmentsizingcanbestarted,aswellasthepowersystemstudies.Apreliminaryloadschedulewillalsoindicateiftherewillbe
problemswithavailablepowersupply/generation,andwhetheralternativepowersourcesorevenprocessdesignswillneedtobeinvestigated.
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