Load Calculation & Load Management Case Study

INDEX
Page No.

1] Introduction 3

1.1) Load Management 4

1.2) Load Calculation 6

2] Electrical Data Collection 7

2.1) Types of Meter 8

2.2) Model electrical Analyzing instrument 9

3] Electrical Motors 12

3.1) Introduction 13

3.2) Energy Efficient Motor 16

4] Refrigeration and Air conditioner 20

4.1) Introduction 21

5] Diesel Generator Set 24

5.1) System Description 25

5.2) Fuel Conversion 27

5.3) Specification 29

6] Transformer 30

6.1) Losses 31

6.2) Transformer Specification 32

7] Illumination 33

7.1) Type of illumination 34

8] Power factor improvement 37

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9] Architecture diagram 40

9.1) Ground Floor 41

9.2) First Floor 46

9.3) Second Floor 50

10] Electrical Equivalent & Formulae 54

10.1) Useful Single Phase & Three Phase Formulae 56

10.2) Recommended Capacitor rating 58

10.3) Section of associated equipment 59

10.4) Earthing Details 60

10.5) Conductor Calculation 61

10.6) Voltage Drop Calculation 62

11] Section chart of MCB’s for house hold appliances 63

12] IS Codes and standards 68

13] Panel designing 70

13.1) Calculation of MCB 71

13.2) Selection of Bus bar 107

13.3) Selection of change over switch 107

13.4) Selection of TPN MCCB 107

14] Distribution Diagram 108

15] Calculation of Transformer Rating 109

16] Calculation of cable Size 111

17] Conclusion 113

18] Bibliography 115

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INTRODUCTION

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1.1 LOAD MANAGEMENT

DEFINATION :-
Load Management or Load Balancing is nothing but equal distribution of load across
Three Phase distribution system during installation.

Load management basically aims at improving the system load factor. The pear demand
is measured by taking half hour average. The highest measurement will be chosen on the peak
demand the maximum demand depends upon the simultaneous running of various machines of the
plant at peak demand. It is possible to record the varying demand directly by recording by recording
meter.
Electrical load management is the process of scheduling load usage to reduce electricity
use during of load peak period. This generally means increasing the electricity consumption during
of load periods.
The major benefits from load management is a reduction in peak demand leading to a
decrease in demand charges.

Comments :-

HP II tariff (P.U.) Paise

Slot I Slot II Slot III Slot IV
22.00 to 6.00 6.00 to 9.00 9.00 to 12.00 18.00 to 22.00
12.00 to 18.00
-85 00 60 120

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1. From TOD tariff it is observed that maximum possible production can taken during the slot I
& II. It will save the electricity bill more , if we adjust the maximum possible production in
this zones.
2. In case of maximum demand ( M.D.) if the sanctioned KVA demand is crossed then it will
cost 150% more for the extra KVA demand
Sanction KVA is 500 KVA
If the KVA demand (M.D.) crosses sanctioned demand i.e. suppose it is 550 KVA once in a
month then it will charge penalty for extra 50 KVA by 150% of demand charges. Demand
charges = 330 Rs./KVA
Therefore 50× 495 = Rs. 24750/-
It will cost almost penalty of rupees 25000/-
3. From electricity bill It is observed that in month of may 2004 KVA demand (M.D.) is 498.00
i.e. almost on verge.
4. It is seen that from M.D. meter reading , it is almost constant around 70 to 75. So by proper
coordination between production department and electrical department, it is possible to
reschedule the few processes to maintain the M.D. with in limits.
5. From the discussion with the company management , it is understood that even if it is
beneficial to set maximum production in slot I & II, practically it seems impossible. Due to
the adjustment of man hours and shift timings.

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1.2 LOAD CALCULATION

DEFINATION:-

Load Calculation is nothing but the observing all the connected load in the desired
premises and differentiate it according to light; load and Power Load of their actual wattage.

STEPS FOR LOAD CALCULATION :-

Note down actual connected load.

Consider approximate wattage suitable for each equipment.

Independent plug & power plug calculate separately.

Consider wattage for independent plug is 300 W & for power plug is 800W to 1500
W.

Differentiate load between light load & power load.

Calculation of load can be made separately for each room.

Compute the computer load without considering the printer & other peripheral devices.

AC, Cooler & 3 phase machinery belongs to the power load.

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ELECTRICAL

DATA COLLECTION

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This is an important stage in the process of energy audit. The data collection process
reveals an idea as to how much energy is utilized and the amount of energy that has been wasted.
The data required for this process is as under:

1. Equipment data/Specifications:
The specifications or data like connected load , motor load , heaters etc.
2. Process or application:
Brief process or application of equipment.
3. Utilization:
In terms of hours per day, per period, per month, per year etc.
4. Loading:
Whether full load or part load and details of average loading over a period.
5. Production out data:
The production out put over a period.
6. Measuring Instruments:
For the measurement of voltage, current , power factor, frequency maximum demand, time
totalizer or equipment utilization counters.

2.1 TYPES OF METERS

The important types of meters are:

1. Indicating meters
2. Recording meters.

1. Indicating meters :
The indicating meters are voltmeter , ammeter and flow meter. These meters are
used to indicate the instantaneous values of operating quantities. These meters have lesser

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utility in an energy audit study as they do not give the energy consumption over s period of
time. They are useful to detect deviations from normal operating conditions.
2. Recording Meters:
These meters are normally used in energy audit practice . They record the
consumption of energy over a period of time. This data will be useful in understanding
energy consumption patterns and thus helpful in taking necessary steps in conservation
studies.

2.2 Modern Electrical Analyzing Instruments

1. Electrical energy analyzer:

These are available with printer. This analyzer generates real-time data for the
analysis of electrical energy use. It records electrical parameters like voltage, current ,
power factor, KVA,KW, power angle at present time interval.

2. Machine utilization counter:

It gives the data machine utilization, running time, ideal time, on load time. It is
basically an energy analyzing instrument.

3. Hand held KVAR meter:

This KVAR meter checks the rating of power factor improving capacitors.

Data collected from various metering systems should be organized properly. The meter
reading should be taken at regular intervals. From the data obtained the major load centers can be
identified. These can also be identified from the connected load data.

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Analysis of data:

This involves a graphical analysis of the obtained data from finding deviations from ideal
conditions. From this analysis the unnecessary usage of wastage can be detected and calculated.
The graphical analysis gives quick and clear picture of the energy consumption pattern.

1. The consumption can be given as:

Consumption = Connected load × Capacity factor × Utilization factor×

Load/ No load factor× No. of hours per day× No. of days. ----- (a)

2. Capacity factor:-
This is the ratio of full load KW used over a connected load.
Where,
√   Ø
Full load KW = ------- (b)



V = Voltage
I = Current
CosØ = Power factor

3. Utilization factor :-
Ratio of hours for which the equipment is in use in one day. This can
be measured on the day- to- day basis or for a period of 100 days by instrument like machine
utilization counter

4. Load / No load factor:-

This is an important factor and has to be established by extensive observations over a
period of time such as one year. During a particular period of time, say 1 hour or 10 hour or 24
hours. The time duration for full load and no load running of equipments or equipment is measured

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with power factor and thus , the power consumed during the load condition and no load conditions
are calculated. The ration of this equipments or equipment is measured with the power factor and
thus the power consumed during the load condition and no load conditions are calculated. The
ratio of this power to no. of hours in use will thus give measure of average load. The load factor is
given by the ration of average full load to the no load.

   

I.e. Load Factor = ------------- (c)
   

The equation (a ) leads to setting up the certain standard norms for equipments or load
center over a period of time. The same can be work out for new equipments without putting the
equipment in actual service if the details such as:

• Connected load.
• Capacity factor.
• Utilization factor.
• Load/ no load factor.
• Working period.
are known.

These norms becomes quite useful to monitor and control before it goes on the side of
variance analysis.

The above norms need to be standardized with the actual standard norms by refining any
slight variance that may occur. The norm is correlated with outputs such as energy consumption
per MVA of transformer or per tone of material or per kiloliter of oil filtered . This will give the out
put norms. Higher and lower consumption can be justified depending upon higher and lower
production. The further planning can be done by these standard norms.

If we consider capacity factor and load/ no load factor , equipment efficiency can be
known and improvement efforts can be made.

Utilization factor and load / no load factor gives fairly good idea about capacity
utilization , operational efficiency etc. of the equipments. From this data , efforts can be made in
the direction so as to improve capacity utilization and operational efficiency , leading to effective
use of energy.

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ELECTRICAL
MOTORS

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3.1 INTRODUCTION

Energy saving Opportunity- Stopping Redundant Running of motors-Oversized motors

Elimination of Voltage unable Drive Transmission efficiency- Energy efficient motors-Energy saving
starter Action Plan.
Electric motors consumer about 75% of the total electrical used for all electrical
application put together. In Nerolac Paints about 83% of electricity is consumed by motors. In the
day of cheap and abundant energy the issue of motors efficiency did not receive high priority .
After the energy crisis, motor and their associated system have received a lot of attention . with
modern power electronic induction motors are replacing many DC and synchronous motors.
In many application, it is worthwhile replacing motors even when considerable working
life remain. Motors can run without problem for 20 year or more, with good protection and routine
maintenance . However if they are running inefficiently , it is worthwhile replacing them as running
costs are much more than first cost . Motor can be considerable as consumable item and not
capital items, considering the current energy prices.

Energy Saving Opportunities :-

1) Stopping idle or redundant running of motors.
In all industrial plants careful study will reveal that some motors are running idle .
In many engineering industries, promised idling of machine tools, conveyors, exhaust fan etc. is
common; stopping of such motors can save 100% of power consumed by these motors. Car may be
taken to stop idle running of auxiliaries like cooling towers, air compressors, pumps etc. during
prolonged stoppage of production machines. Redundant running implies that equipment is
working without any effect on the production quantity and quality. Unless these are operating
from safety considerations, stoppage of these motors can led to large saving e.g. operation of
cooling towers , fans or air conditioning system when ambient conditions are favorable .
2) Oversized motors :-

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The efficiency of motors is nearly constant up to 60% shift load and then drops sharply at
lower load. However power factor drops continuously with shaft load. The efficiency of motor
operating at load below 60% is likely to be poor and energy saving are possible by replacing these
with properly sized motor. These situations usually arise due to over specification by the user or
large safety margins kept by the original equipment manufacture .

Oversize motor leads to following problems.

• Higher installation cost.

• Higher investment cost due to the larger size.
• Higher running cause due to decrease in efficiency.
• Higher maximum demand due to power factor.
• Higher space requirement .
• Higher rewinding cost ( In case of motor burnout ).

3) Elimination of voltage unbalance:-

Voltage unbalance degrades the performance and shortens the life of three phase motor.
Voltage unbalance at the motor start terminals causes phase current unbalance far out of
proportional to the voltage unbalance. Unbalance current lead to torque pulsation increase
vibration and mechanical stress, increased losses and motors overheating which results in shorter
winding insulation life. Voltage un balance is defined as 100 times the absolute value of the
maximum deviation of the line voltage from the average on a three phase system, divident by the
average voltage. It is recommended that the voltage unbalance at the motor terminal not exceed
1%. A 1% unbalance will increase the motor losses by 5%.

These voltage fluctuation is common phenomenon in the various industries 70% of

industrial load is of motors . Electrical motor draw considerably high current at low and high
voltage. These high currents affects the electrical motors in three ways

Higher current produce higher losses in electrical motors, which causes premature failure
of winding.

These higher losses of electric motors also increase the losses of cables , switches,
transformer and other associated equipment.

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For smooth continuous operations of motors over load, relays are usually set at 20%
higher setting.

The efficiency of rewound , 1800 rpm, 100 HP motor is given an function of voltage
unbalance and motor load in the table. The general trend of efficiency reduction with increased
voltage unbalance is observed for all motors at all load conditions.

Motor load % Motor efficiency (%)

Full load Voltage unbalance
Nominal 1% 2.5%
100 94.5 94.4 93.0
75 95.2 94.1 93.9
50 96.1 95.5 94.1

Table 1.1 Motor Efficiency under conditions of voltage unbalance.

Voltage unbalance due to single phasing.

4. Single phasing may cay cause following adverse effect:

The line current increase by 1.5 times .

If the relay setting is at 20% higher than actual operating current then the relay will take 4-6
minutes to trip.

The motor ( Particularly smaller capacity motors up to 7.5 HP) can not withstand this high
current for such a long time and in most of the cases, it barns out before the relay trip.
Heavy short circuit current flows through the relay contactors, cable etc.
Under these condition when the relay, con trip, they produce sparks and some time burns
This further damage the switchgear are in some of the cases may cause fire also.
With the installation of the stabilizer and maintaining 415 Volts. The motor will operative
smoothly drawing 15-20% lesser current and correspondingly the relay setting can be reduced by
15-20%. In case single phasing occurs , the relay will trip in

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40-50 Seconds . The motors can withstand the high current for this period and will be safe. Also ,
the relay contactors switchgear etc. in with the motor, will be safe.

Advantage:-

• Reduction in breakdown of electrical equipment.

• Energy saving.
• Improvement in power factor.
• Uniform Quality of end product.
• 100% depreciation as per income tax act.

5) Drive transmission efficiency

About one third of the electric motors in the industrial and commercial sector use belt
drives. Belt drive provides flexibility in the position of the motor relative to the load. Pull eye of
varying diameters allows the spread of the driven equipment to be increase or decrease. A properly
designed belt transmission system provides high efficiency, low noise does not require lubrication
and present law maintenance requirement. However, certain types of belts are more efficient than
others, offering potential energy cost saving.

The majority of belt drives use V- belts. V-belts use a trapezoidal cross section to create a
wedging action on the pulleys to increase fraction and belts power transfer capability. Join or
multiple belts are specified for heavy loads. V – belts driven can have peak efficiency of 93% at the
time of installation efficiency is also depend on pulley size, driven torque, under over belting and V-
belt design and construction efficiency deteriorates by as much as 5% ( below 90% over tine if
slippage , occurs because the belt is not periodically re-tensioned.

3.2 Energy Efficient Motor

In industries the major utilization of energy is done by motor for total energy supplied to
industries about 75% is utilized by motors. There are various kinds of motors which are use in
industries of this synchronous motors accounts for only 5% of the load and DC motors utilize 10%

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of the total load. The maximum load of 60% is consumed by induction motors. Hence by reducing
the consumption of energy by induction motor prove to be a great milestone for energy
conservation, due to such statistics a major focus is done on the development of energy efficient
motors.

Performance characteristics of energy efficient motors.

Stator and copper losses are of the order of 60%. Copper losses can be reduced by reduction
conductor resistant. It is achieved by increasing area of cross section of stator winding and motor
bars.

Friction and windows , losses are of the order of 10% friction loss is reduced by use of
improved bearing. In order to reduced the wind age loss far size can reduced. Performance of EEM
is better an compared to standard motors not only full load condition but also under partial no load
conditions.

Advantages of Energy Efficient Motors :-

a) Energy saving features :-

An energy efficient motor produces a given amount of work with less
energy than standard motors. Energy efficient motor on the other hand use
better quality copper and which in turn in high energy saving.

b) Reduced cost :-

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Although the first cost of energy efficient motor is slightly higher than standard motors,
life cycle cost can make them more economical due to saving they generation in operating
expenses. On an average the standard motors incur around the twice the operating cost while
comparing to energy efficient motors.

c) Longer Life :-
Energy efficient motor runs cooler than their standard counter parts, resulting in
increased motor insulation and bearing life. In general an efficient motor ensuring fewer
winding failure, longer period’s bun needed maineenanu and fewer forced outage.

d) Optimum Efficiency :-

Nearly all motors operates below full load for most of their running time .
Energy efficient motor has been designed to ensure that the energy saving
benefits are maintained on matter whether the motor is running at half thru four
our full load.

6) Energy Saving Starters:-

There are many application where motor runs on light load for considerable time.
Conveyors agitators, mixture and machine tools are typical example. Some of this application
requires large starting torque for an extended starting period and the system inertia is large. For
all such applications , reduction of motor size is not possible. There are two points available for
user to save energy.

a) Running data connected motor in star connection when the motor is lightly loaded.
b) Use soft started with energy saving feature at partial loads.

• Operation of delta connection motor in star connection.

The motor characteristics are normally available at rated voltage. At any other
voltage the motor would exhibits different performance characteristics. Many
motors are data connected in normal running condition, only starting may be
in star connection facilitated by a star delta started. If these motors are
operated in star connection continuously, the performance characteristic

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would be different. The following recommendations may be made.
• If the motor is oversized and the drive has not abnormal starting requirement. The motor
may be permanently connected in star connection and started direct – on-line.
• If the motor is oversized runs continuously at load below 55%, but has large starting
torque, transformer starter during normal continuous load. The motor may be connected
in star by timer control changeover.
• If the motor is nearly always operating above 55% of the rated load, and runs on the
occasionally at below 55% of load, a careful analysis is required, before installing an
arrangement for operation in star connection at light loads.
• Soft starter cum energy savers

These are motor controllers applied to motor for a smooth start and save energy for
lightly loaded motors. Studies have shown that the energy saving obtained by installing soft starter
are dependence on the loading of the motor. Saving are pronounced for motor loading been 10-
55%. However if the load is higher than 55% of the rated. Soft starters are generally small and
simple pay back periods are long, so the decision to use soft starters should not be only based on
the anticipated cost saving alone. If should be noted that energy saving properties of soft starters
may adversely affects the stability of certain drive system due to reduction of developed torque.
Soft starters also distract current drawn from the utility and so the decision for installation so
starter has to be taken after serious consideration of these issues.

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REFRIGERATION
AND AIR
CONDITIONING

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4.1 INTRODUCTION

Refrigeration is the process for removing heat at low temperature level and rejecting it
at relatively higher level temperature. Refrigeration is accomplished by various methods such as
vapour compression system, vapour absorption sysyem and stem jet refrigeration cycle . The most
common used systems are vapour compression and vapour absorption.

The item required for the makeup complete refrigeration an air conditioning systems
are refrigerating equipments, fans, pumps, cooling towers, filters, air handling units and ducting.
Depending upon the process all or some of the item mentioned may required.

Two mainly used refrigeration systems –

1. Vapour compression system

2. Vapour absorption system
1. Vapour Compression system
Vapour compression system has following features.
i) Absorbing heat by evaporation of a liquid refrigerant in the evaporator at a controlled
low pressure.
ii) Raising the pressure of the pressure of the low pressure vapour coming from evaporator
by using the compressor.
iii) Removing heat by high pressure vapour in condencer so as to liquefy or condense the
vapour.
iv) Reducing pressure of high pressure liquid to level needed in the evaporator by using the
throttling device.

Efficiency of vapour compression system does not depend on compressor alone. The
compressor will work efficiently only when heat exchange, that is evaporator , chiller and
condenser operates efficiently.

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Performance evaluation

An air conditioning and refrigerant plant is efficient when all the systems components
that is compressor, condenser , evaporator and condenser cooling system are work in a matched
condition it means that under peak operating condition they must perform their optimum output.

Compressor

The operating KW input can give the value of input power. This can compare with rated
input

Condenser

Water or air flow rate and temperature rise across the condenser also give the heat
rejection. The flow rate and temperature rise should be compare with designed parameters.

KW = 4.182×(Liter/ sec) ×Δ T0C

Chiller

Water or brine flow rate and temperature drop across the chiller gives the cooling flow
rate and temperature drop should be compare with design parameters.

BTU/hrs =GPM (US)× Specific Heat ×Specific gravity× Δ T0F/24

KW = 4.182×(Liter/ sec) × Specific Heat ×Specific gravity × Δ T0C

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Cooling Coil

Air flow rate and enthalpy drop across the cooling coil will give cooling load. Flow rate and
enthalpy drop should be compared with designed parameters.

BTU = 4.5× CFM×ΔH ( Chang in Enthalpy)

KW = 1.2 ×(Liter/ sec)× ΔH (Kj×Kg)

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DIESEL GENERATING
SET

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Depending upon type of industry, its setting and magnitude of connected load, DG sets
are employed in various modes like

1. The stand by mode to meet a part or full requirement of the plant in case of power failures .
2. The peak load mode to meet the requirement during peak demand, there by reducing the
maximum demand.
3. The base load mode, where a part or whole of the plants requirement is met on the
continuous basis.
4. The total energy mode, where it not only supplies the total power required but also meets
the heating and cooling requirements of the plant by utilizing the waste heat from the DG
set exhaust in an integrated system.

5.1 System Description

DG set consist of prime mover and an alternator. The prime mover is , invariably , a
compression ignition engine.

In the prime mover heat energy of fuel is conserved in to the mechanical energy
through the rotatory motion of the output shaft of the engine. The output shaft is directly coupled
to an alternator which gives a electric power , therefore in principle DG set consists of two main
subsystems.

• An international Combustion engine

• An alternator

For all the practical purpose , while conducting an energy audit of DG set is the engine
or prime mover part which is concentrated upon. International

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combustion engine is considered energy efficient compare to their predecessor, external
combusting engine. But efficiency level of typical engine is only about 26%.

Energy Input (100%)

Exhaust Energy cooling Indicated Hourse

power
(34%) (30%)

Frictional & Brake Hourse

other losses Power
(10%) (26%)

As can be shown in figure of total energy input,34% is lost throughout the exhaust, 30% to
the cooling media, and only remaining 36% is converted to useful work, defined as indicated power.
Of this another 10% is lost as engine friction and other losses. Thus the out of 100 units of energy
that goes in to the system, only 25% is available at the output shaft.

In a system like DG set, more often than not, the end user needs to contact to manufacturer
for the remedy of particular problem. On the user part , identification of the problem, therefore
assume a much greater role.

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5.2 Fuel conversion

In the DG set, reduction of fuel consumption, even by a small percentage , can need to
enormous monetary saving. But the first step to approach the problem is to assess the operating
efficiency of the DG set. This will indicate if there is any scope of affect savings, and if so, by how
much. The efficiency of DG set is combine efficiency of the engine and the alternator. The overall
efficiency is therefore defined as the number of units electricity generated per liter fuel
consumption. The resultant figure is called SEGR ( Specific Electricity Generation Ratio) with the
unit of KWh/Ltr.

If actual SEGR found to be lower than normative value recommended by manufacturer, the
efforts would be made to identify this deviation. The nature of problem could be range from
improper fuel injection to accessive wear and tear in the ring / linear assembly leading to high
blown – by a subsequent power loss. It is very difficult to rectify some of these faults at user and
help of manufacturer become necessary. There are areas , however, where the DG set user can
himself take remedial actions. Some of these measures are discussed below.

5.2.1 Proper engine loading

One must always take care to ensure that, to the extent possible, the sets are optimally loaded.
Specifically in cases where there are more than one or a bank of DG sets, proper load distribution
among the sets can yield rich benefits.

5.2.2 Lubricating oil

Choice of lubricant is important and can help in reducing friction losses as a result, fuel
consumption.

It is always preferable to use multi grade oil in place of mono grade oil.

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5.2.3 Waste heat recovery

The record waste heat could be used for one or more application below

• Pre-heater combustion air

• Hot water generation
• Waste- heat boiler for system generation
• Vapour absorption refrigeration system

5.2.4 Fuel additives

Fuel additives are generally used to tackle specific problems and are restored to when conventional
methods fail.

Lubricating oil conservation:-

For engine application , lubricating oil should have specific heat characteristics for desirable
performance. The finish lubricants are , therefore , high value products and need to be used
efficiently.

The three main ways to achieve lubricant conservation are

1. Reduction in oil consumption

2. Re-refilling of used oil
3. Optimizing the drain interval .

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5.3 Specifications

Rating 50 KVA

Power factor 0.8

Voltage 415 V

Current 125 amp

Insulation class H

Generator Model KG50 WS

Noise Limit 75 dB at 1 mtr.

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TRANSFORMER

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6.1 LOSSES

Energy saving potential in the transformer largely depend on its loading

pattern. The operation of the transformer is based on Faraday’s law of induction. Using right
choice of power level & location , it is possible to achieve an optimal utility of transformers. All the
operating transformers have operating losses that can be broadly classified as

1. Open circuit losses ( iron losses in the core and Ohomic losses of the open circuit current).
2. Short circuit losses ( conductor and eddy current losses)
- Open circuit losses are independent of quantum of power being transform by
the transformer. These losses can be minimized design modification and through improved
construction, i.e., rising the cross section of the limb or using the novel ferromagnetic material . the
short circuit losses increase with the square of the power being transferred to the transformer.
Short circuit losses can only be lowered by increasing the cross section of the conductors of the
windings.

- Reduction of the transformer losses

The total losses (P) of transformer during operation high


P = P0+ (   )2× Psc


Where ,

P = Total power losses in KW

P0 = open circuit losses in KW

Psc = Short circuit losses in KW

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Ps = Actual load of transformer in KVA

Pn = Rated power of transformer in KVA

The total losses in the transformer is of two types, one is constant and the other increases
with the square of the load. Normally, open circuit losses (P0) are of the order of 0.2% to 2.5% of
nominal power , where as , the short circuit losses (Psc) are 0.7% to 2.1% of nominal power .

When planning the installation of a new transformer in an electrical system, it is

necessary to compare different design of transformer. A special transformer with reduced open
circuit losses might be of interest.

At time of installation of a new transformer, size or a capacity is decided based on

expected loading on transformer. Normally, maximum efficiency of transformer on loading is
designed to be the range of 50% to 65% of its full load capacity. If average load is 80% or more of
the rated power, a bigger transformer or a second transformer should be considered because the
short circuit losses amount to a large portion of the total losses.

6.2 Transformer specification

KVA rating - 150 KVA

Current - H.V. Side: – 14 amp.

- L. V. Side: – 1064 amp

Oil - 350 liter

Connections - λ /Δ- DY-11(1994)

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 Load Calculation & Load Management Case Study

ILLUMINATION

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 Load Calculation & Load Management Case Study

7.1 TYPES OF LIGHTING

A lumen is measure of light output from lamp. The distribution of light on horizontal
surface is called its illumination. Which is measured in foot candles or lux.

- Lightning can be divided in three categories

1. Ambient
2. Task
3. Accent
1. Ambient lighting provides security and safety as well as general illumination for performing
daily activities.
2. Task lighting is to provide enough illumination so that task can be completed accurately. The
entire area is not illuminated.
3. Accent lighting illuminates walls to blend more closely with naturally bright areas like ceiling
and windows.
- There are four basic types of lighting.

1] Incandescent lamps are the least expensive to buy but the most expensive to operate. The
light is produced by tiny coil of tungsten wire that blows when heated by electric current.

The three most common types of incandescent lights are

i) Standard Incandescent
ii) Tungsten Halogen
iii) Reflector Lamps

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 Load Calculation & Load Management Case Study

i) Standard Incandescent :–
Known as ‘A type light bulb’. These lamps are the most common, yet the most
inefficient light source available. Larger wattage of higher efficiency than smaller
wattage bulbs.
ii) Tungsten Halogen : –
This type of incandescent lighting is having better energy efficiency than standard
‘A type bulb’. It has gas filling and inner coating that reflects heat.
The felling and coating recycle heat to keep filament hot with less electricity. These
are most expensive and use for commercial applications.

iii) Reflector Lamps : –

These lamps are designed to spread light over specific areas . They are use mainly
indoors for stage /theatre , store, flood lighting, spot lighting etc.

2] Fluorescent : –

The light produced by fluorescent tube is caused by electric current conducted through
inert gases like mercury. Fluorescent is used mainly indoors, both for ambient and task lighting and
it is three to four times efficient than incandescent lighting. For optimum efficiency of lamp , it
should be installed in place where they will remain on for several hours at a time.

Ballast which are used in Fluorescent lamps for starting and circuit protection, consumes
energy.

Compact Fluorescent lamp :–

Compact fluorescent lamps (CFLs) are the most significant lighting devices developed for
homes on recent years. They combined the efficiency of fluorescent lighting with the continuous
and popularity of incandescent fixtures.

CFLs can replace incandescent once that are roughly three or four times wattage, saving
up 75% of initial energy.

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 Load Calculation & Load Management Case Study
Although CFLs cost from 10 to 20 times more than comparable incandescent bulbs, they
last 10 to 15 times long.

3] High Intensity Discharge :–

The HID (High Intensity Discharge) lamps provide the highest efficiency and longest
service of any lighting type. They are use for outdoor lighting and large indoor areas. HID lamps are
used an electric arc to produce intense light. The most common types of HID lamps are
i) Mercury Vapour
ii) Metal Halid
iii) High Pressure Sodium
iv) Low Pressure Sodium

HID lamps and fixtures can save 75% to 90% of lighting energy when replace
incandescent lamps.

i) Mercury Vapour :–

This is oldest type of HID lighting and is used to street lighting. It provide 50 lumen per watt.

ii) Metal Halid :–

These are similar to mercury vapour lamps in construction and appearance . but additional of
metal halid gases to mercury gas in a lamp results higher output, more lumens per watt and
better colour radiation. Metal halid lamps are used for large indoor areas like sports arenas.

iii) High Pressure Sodium :–

This lamp provides 90 to 150 lumen per watt. It has high efficiency exceeded only by low
pressure sodium lighting. High pressure lamps are reliable and have long service lives.

iv) Low pressure sodium :–

Low pressure sodium lamps work in some ways like fluorescent lamps. They are most efficient
artificial lighting. It has longest service life. It is used where colour is not important.

S.S.P.M.’s COE. 36
 Load Calculation & Load Management Case Study

POWER FACTOR
IMPROVEMENT

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 Load Calculation & Load Management Case Study
Power factor is defined as a ration of real power (KW) to the apparent power (KVA) and is
the cosine of angle by which current large or lead the voltage.

In case of inductive load , current lags the voltage and power factor is the lagging ; where as
in case of capacitive loads, current leads the voltage and power factor is leading.

Most industrial loads are like motors, welding sets, light sources using ballasts etc. are
inductive in nature and overall power factor of the plant is low and lagging. The poor power factor
results increased reactive current that, in terns , increase total current drawn by the system. The
total current is vector sum of reactive and working components of the current.

It =  ! "

Where,

It = Total current

Iw = working component of the total current

Im = Magnetizing component of the total current

With an increase in total current drawn, the I2 R losses in the line increases which also
results in greater voltage drop across the line leading to poor voltage regulation. Poor power factor
also results in increase the reactive power , leading to increased KVA demand by

KVA = It = # ! #$%&

Where,

KVA = Aperant power

Kw = Real Power

KVAR = Reactive component of power

-
-

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 Load Calculation & Load Management Case Study
Methods of improving power factor

Poor power factor can be improved by using shunt capacitors or by using synchronous
condensers that can be operated at leading power factor to compensate for a loads with lagging
power factor.

S.S.P.M.’s COE. 39
 Load Calculation & Load Management Case Study

ARCHITECTURE
DIAGRAM

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 Load Calculation & Load Management Case Study

GROUND FLOOR
Name of Name of Wattage of
Sr. No. of
the Class the single Total Watt
No. Equipments
Room Equipment Equipment
Fan 9 100 900
Class
Tube light 8 40 320
1 Room
I.P. 2 300 600
No.1
Grand total of Watt 1820
Fan 9 100 900
Class
Tube light 8 40 320
2 Room
I.P. 2 300 600
No.2
Grand total of Watt 1820
Fan 9 100 900
Class
Tube light 8 40 320
3 Room
I.P. 2 300 600
No.3
Grand total of Watt 1820
Fan 9 100 900
Class
Tube light 8 40 320
4 Room
I.P. 2 300 600
No.4
Grand total of Watt 1820
Tube light 3 40 120
5 Toilet C.F.L. 2 20 40
Grand total of Watt 160
Fan 2 100 200
Store Tube light 4 40 160
6
Room I.P. 2 300 600
Grand total of Watt 960
Fan 15 100 1500
Seminar Celing
7 22 20 440
Hall No.1 Lamp
15 A. P.P. 4 800 3200

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 Load Calculation & Load Management Case Study

Grand total of Watt 5140

Fan 15 100 1500
Seminar Ceiling Lamp 22 20 440
8 15 A. P.P. 4 800 3200
Hall No.2
Grand total of Watt 5140
Fan 1 100 100
Court- Ceiling
9 4 20 80
Yard- I Lamp
Grand total of Watt 180
Fan 1 100 100
Court- Ceiling
10 4 20 80
Yard-II Lamp
Grand total of Watt 180
Fan 2 100 200
Meeting C.F.L. 8 20 160
11
Room - I 15 A. -P.P. 2 1500 3000
Grand total of Watt 3360
Fan 3 100 300
Meeting C.F.L. 7 20 140
12
Room - II 15 A. -P.P. 1 1500 1500
Grand total of Watt 1940
Fan 1 100 100
C.F.L. 2 20 40
Ir. Trustee
13 Tube light 1 40 40
Room
15 A. -P.P. 1 1500 1500
Grand total of Watt 1680
Tube light 4 40 160
14 Toilet C.F.L. 4 20 80
Grand total of Watt 240
Fan 8 100 800
C.F.L. 12 20 240
P.C. 8 500 4000
15 Office
Printer 2 500 1000
15 A. -P.P. 3 800 2400
Grand total of Watt 8440
16 Lab. No. 1 Fan 7 100 700
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 Load Calculation & Load Management Case Study

Tube light 9 40 360

I.P. 26 500 13000
15 A. -P.P. 2 1500 3000
Grand total of Watt 17060
Fan 8 100 800
Tube light 10 40 400
17 Lab. No. 2 I.P. 14 500 7000
15 A. -P.P. 2 1500 3000
Grand total of Watt 11200
Fan 1 100 100
Tube light 1 40 40
Registrar
18 C.F.L. 2 20 40
Room
15 A. -P.P. 1 1500 1500
Grand total of Watt 1680
Fan 7 100 700
Tube light 9 40 360
19 Lab. No. 3 I.P. 12 300 3600
15 A. -P.P. 2 1500 3000
Grand total of Watt 7660
Fan 7 100 700
Tube light 9 40 360
20 Lab. No. 4 I.P. 11 300 3300
15 A. -P.P. 2 800 1600
Grand total of Watt 5960
Fan 2 100 200
C.F.L. 4 20 80
Principal I.P. 1 500 500
21
Cabin Tube light 3 40 120
15 A. -P.P. 1 1500 1500
Grand total of Watt 2400
Fan 15 100 1500
Tube light 23 40 920
22 M/C Lab
Motor 1 30 H.P. 22500
Grand total of Watt 24920
23 Toilet Tube light 7 40 280

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 Load Calculation & Load Management Case Study

Grand total of Watt 280

Fan 10 100 1000
Tube light 24 40 960
24 B.E.E. Lab.
I.P. 26 300 7800
Grand total of Watt 9760
Fan 9 100 900
I.P. 12 500 6000
25 C.S. Lab. Tube light 11 40 440
15 A. -P.P. 2 800 1600
Grand total of Watt 8940
Fan 2 100 200
H.O.D. Tube light 5 40 200
26
Electrical I.P. 2 500 1000
Grand total of Watt 1400
Fan 7 100 700
B.E. Class Tube light 11 40 440
27
Room I.P. 2 500 1000
Grand total of Watt 2140
Fan 7 100 700
T.E. Class Tube light 11 40 440
28
Room I.P. 2 500 1000
Grand total of Watt 2140
Fan 1 100 100
I.P. 1 500 500
29 C.S. Lab. Tube light 1 40 40
C.F.L. 2 20 40
Grand total of Watt 680
15 A(PP)
Cooler 1 1500 1500
I.P. 6 300 1800
30 Spear Tube light 15 40 600
C.F.L. 20 20 400
Grand total of Watt 4300

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 Load Calculation & Load Management Case Study

LOAD ON GROUND FLOOR IN K.W.

Sr.
Name of the Room Load in Watt Load in Kilo Watt
No.
1 Class Room 1 1820 1.82
2 Class Room 2 1820 1.82
3 Class Room 3 1820 1.82
4 Class Room 4 1820 1.82
5 Toilet 160 0.16
6 Store Room 960 0.96
7 Seminar Hall No.1 5140 5.14
8 Seminar Hall No.2 5140 5.14
9 Court yard – 1 180 0.18
10 Court yard – 2 180 0.18
11 Meeting Room -1 3360 3.36
12 Meeting Room -2 1940 1.94
13 Jr. Trustee Room 1680 1.68
14 Toilet 240 0.24
15 Office 8440 8.44
16 Lab. 1 17060 17.06
17 Lab. 2 11200 11.2
18 Registrar Room 1680 1.68
19 Lab. 3 7660 7.66
20 Lab. 4 5960 5.96
21 Principal Office 2400 2.4
22 M/C Lab. 24920 24.92
23 Toilet 280 0.28
24 B.E.E. lab. 9760 9.76
25 CS Lab. 8940 8.94
26 HOD Cabin 1400 1.4
27 B.E. Class Room 2140 2.14
28 T.E. Class Room 2140 2.14
29 T.P.O. Room 680 0.68
30 Spear 4300 4.3
Total 135220 135.22

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 Load Calculation & Load Management Case Study

FIRST FLOOR
Name of Name of Wattage of
Sr. No. of
the Class the single Total Watt
No. Equipments
Room Equipment Equipment
Fan 9 100 900
Class Room Tube light 6 40 240
1
No.1 I.P. 2 800 1600
Grand total of Watt 2740
Fan 9 100 900
Class Room Tube light 6 40 240
2
No.2 I.P. 2 800 1600
Grand total of Watt 2740
Fan 9 100 900
Class Room Tube light 6 40 240
3
No.3 I.P. 2 800 1600
Grand total of Watt 2740
Fan 9 100 900
Class Room Tube light 6 40 240
4
No.4 I.P. 2 800 1600
Grand total of Watt 2740
Fan 9 100 900
Tube light 1 40 40
Class Room
5 I.P. 2 800 1600
No.5
C.F.L. 9 20 180
Grand total of Watt 2720
Fan 9 100 900
Tube light 1 40 40
Class Room
6 I.P. 2 800 1600
No.6
C.F.L. 9 20 180
Grand total of Watt 2720
Fan 6 100 600
Tube light 4 40 160
7 lab. 1 A.C. 2 1500 3000
P.C. 24 500 12000
Grand total of Watt 15760

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 Load Calculation & Load Management Case Study

Fan 8 100 800

Tube light 10 40 400
8 lab. 2 A.C. 2 1500 3000
P.C. 25 500 12500
Grand total of Watt 16700
Fan 6 100 600
Tube light 8 40 320
9 lab.3 A.C. 1 1500 1500
P.C. 22 500 11000
Grand total of Watt 13420
Fan 9 100 900
Tube light 10 40 400
10 lab.4
I.P. 2 300 600
Grand total of Watt 1900
Fan 12 100 1200
Tube light 18 40 720
11 lab.5 A.C. 2 1500 3000
P.C. 30 500 15000
Grand total of Watt 19920
Fan 12 100 1200
Tube light 20 40 800
12 lab.6 A.C. 2 1500 3000
P.C. 30 500 15000
Grand total of Watt 20000
Fan 9 100 900
Class Room Tube light 11 40 440
13
No.7 I.P. 2 500 1000
Grand total of Watt 2340
Tube light 5 40 200
14 Toilet
Grand total of Watt 200
Fan 9 100 900
Class Room Tube light 11 40 440
15
No.8 I.P. 2 500 1000
Grand total of Watt 2340

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 Load Calculation & Load Management Case Study

Fan 9 100 900

Class Room Tube light 11 40 440
16
No.9 I.P. 2 500 1000
Grand total of Watt 2340
Fan 2 100 200
H.O.D. Tube light 5 40 200
17
Electrical I.P. 2 500 1000
Grand total of Watt 1400
Tube light 3 40 120
18 Toilet C.F.L. 5 20 100
Grand total of Watt 220
19 Cooler 1500
Grand total of Watt 1720

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 Load Calculation & Load Management Case Study

LOAD ON FIRST FLOOR IN K.W.

Sr.
Name of the Room Load in Watt Load in Kilo Watt
No.
1 Class Room No.1 2740 2.74
2 Class Room No.2 2740 2.74
3 Class Room No.3 2740 2.74
4 Class Room No.4 2740 2.74
5 Toilet 220 0.22
6 Cooler 1500 1.5
7 Class Room No.5 2720 2.72
8 Class Room No.6 2720 2.72
9 Lab. No. 1 15760 15.76
10 Lab. No. 2 16700 16.7
11 Lab. No. 3 13420 13.42
12 Lab. No. 4 1900 1.9
13 Toilet 200 0.2
14 Lab. No. 5 19920 19.92
15 Lab. No. 6 20000 20
16 Class Room No.7 2340 2.34
17 Class Room No.8 2340 2.34
18 Class Room No.9 2340 2.34
19 H.O.D. Cabin 1400 1.4
Total 114440 114.44

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 Load Calculation & Load Management Case Study

SECOND FLOOR
Name of Name of Wattage of
Sr. No. of
the Class the single Total Watt
No. Equipments
Room Equipment Equipment
Fan 8 100 800
Class Room Tube light 10 40 400
1
No.1 I.P. 2 800 1600
Grand total of Watt 2800
Fan 8 100 800
Class Room Tube light 7 40 280
2
No.2 I.P. 2 800 1600
Grand total of Watt 2680
Fan 7 100 700
Class Room Tube light 11 40 440
3
No.3 I.P. 2 800 1600
Grand total of Watt 2740
Fan 7 100 700
Class Room Tube light 11 40 440
4
No.4 I.P. 4 300 1200
Grand total of Watt 2340
Fan 9 100 900
Tube light 2 40 80
Class Room
5 I.P. 2 500 1000
No.5
C.F.L. 8 20 160
Grand total of Watt 2140
Fan 9 100 900
Tube light 2 40 80
Class Room
6 I.P. 2 500 1000
No.6
C.F.L. 8 20 160
Grand total of Watt 2140
Fan 9 100 900
Tube light 2 40 80
Class Room
7 I.P. 2 500 1000
No.7
C.F.L. 8 20 160
Grand total of Watt 2140

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 Load Calculation & Load Management Case Study

Fan 9 100 900

Tube light 2 40 80
Class Room
8 I.P. 2 500 1000
No.8
C.F.L. 8 20 160
Grand total of Watt 2140
Fan 8 100 800
Tube light 6 40 240
9 lab.1 P.C. 1 500 500
I.P. 10 300 3000
Grand total of Watt 4540
Fan 8 100 800
Tube light 10 40 400
10 lab.2
I.P. 12 300 3600
Grand total of Watt 4800
Fan 12 100 1200
Tube light 18 40 720
11 lab.3 P.C. 7 500 3500
I.P. 30 300 9000
Grand total of Watt 14420
Fan 10 100 1000
Tube light 24 40 960
12 lab.4 P.C. 3 500 1500
I.P. 28 300 8400
Grand total of Watt 11860
Fan 4 100 400
Tube light 3 40 120
13 lab.5
I.P. 10 300 3000
Grand total of Watt 3520
Fan 2 100 200
H.O.D. Tube light 4 40 160
14
EXTC I.P. 2 500 1000
Grand total of Watt 1360
Tube light 10 40 400
15 Toilet
Grand total of Watt 400

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 Load Calculation & Load Management Case Study

Tube light 3 40 120

16 Toilet C.F.L. 5 20 100
Grand total of Watt 220
Fan 11 100 1100
Basement Tube light 12 40 480
17
Load I.P. 6 1000 6000
Grand total of Watt 7580

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 Load Calculation & Load Management Case Study

LOAD ON SECOND FLOOR IN K.W.

Sr.
Name of the Room Load in Watt Load in Kilo Watt
No.
1 Class Room No.1 2800 2.8
2 Class Room No.2 2680 2.68
3 Class Room No.3 2740 2.74
4 Class Room No.4 2340 2.34
5 Class Room No.5 2140 2.14
6 Class Room No.6 2140 2.14
7 Class Room No.7 2140 2.14
8 Class Room No.8 2140 2.14
9 Lab. No. 1 4540 4.54
10 Lab. No. 2 4800 4.8
11 Lab. No. 3 14420 14.42
12 Lab. No. 4 11860 11.86
13 Lab. No. 5 3520 3.52
14 Toilet 220 0.22
15 Toilet 400 0.4
16 H.O.D. Extc. 1360 1.36
17 Basement Load 7580 7.58
Total 67820 67.82

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ELECTRICAL UNITS
EQUIVALENTS &
FORMULAE

S.S.P.M.’s COE. 54
 Load Calculation & Load Management Case Study

1H. P. = 746 Watts 0.746 KW = 33,000 ft . Lbs per minute = 1.014

1 Metric H. P. 0.735 KW (Kilowatts)

1 B.O.T Unit 1,000 Watt Hours of 1 Kilowatt Hours

Torque (ft. L B.) (H. P. ×33.000) /RPM × 2)

Current Watt/Volts

Motors Output in H. P. (kilowatt input ×Efficiency)/0.735

K.V.A. (volts × Amps)/1000

Power Factor Ratio of True Power/Apparent Power Kilowatt/K.V.A.

True power in 3 phase circuit in Kilowatt (1.73×Volts ×Amps× P.F.)/100

Single Phase Motor Amperes H. P. ×735/ Efficiency× volts×P.F.)

1 Electrical Units 1 Kilowatt hour

1 Kilowatt (K. W. H.) 1 Kilowatt hour

7.38 ft. per Sec.

1.341 horse power

1.360 Metric horse power

1Kilowatt hour (K. W. H.) 3.413 B. Th. U

860 Calories

1 Foot pound (ft.lb) 0.1383 Mkg.

1 B Th U 778.3 ft. lb

107.6 Mkg

0.2520 Calories
1 Calorie (call) 3.088 Foot pounds

3.968 Th. U.

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 Load Calculation & Load Management Case Study

10.1 USEFUL THREE PHASE FORMULE

K.W. = KVA × Power factor

' ()*
K.W. =

 ( +,,-./0.1 0

2-0/ 345 (2-0/ 67 (

.) ( .9.
K.W. =


:.;.
K.V.A. = .9.

' ()*
K.V.A. =
 ( +,,..9.

2-0/ 345 (2-0/ 67 (

.)
K.V.A. =



K.V.A. = #< ! #$%&

:..3.(

Line Amps = 2-0/ 67 (
.)

'..()*
Line Amps = 2-0/ 67 (
.)
(+,,.(.9.

:.;.(
(+,,0
H.P. =
)*

:..3.(
(+,,0(.9.
H.P. =
)*

2-0/ 345 (2-0/ 67(

.) (+,,0(.9.
H.P. =
)*

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 Load Calculation & Load Management Case Study

CALCULATION OF LOAD FROM THE REVOLUTIONS OF ENERGY METER

K = Mrter constant in revolutions / K Whr.

n = No. of Revolutions selected
t = Time in seconds for n revolution
=
The load in K.W. =
:.7

WELDING TRANSFORMERS
KVA Rating or Reqiured Capacitor KVA Rating of Required
Teansformer Rating in KVAR Transformer Capacitor Rating
in KVAR
9 4 36 18
12 6 57 25
18 8 95 45
24 12 128 50
30 15 160 75

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 Load Calculation & Load Management Case Study

10.2 Recommended Capacitor Rating

RECOMMENDED CAPACITOR RATING

For direct connection in induction motors to improve power factor to 0.95
or better at all loads
KVAR rating when motor speed is
Motor 3000 1500 1000 750 500
H.P. r.p.m. r.p.m. r.p.m. r.p.m. r.p.m.
2.5 1.0 1.0 1.5 2.0 2.5
5.0 2.0 2.0 2.5 3.5 4.0
7.5 2.5 3.0 3.5 4.5 5.5
10.0 3.0 4.0 4.5 5.5 6.5
15.0 4.0 5.0 6.0 7.5 9.0
20.0 5.0 6.0 7.0 9.0 12.0
25.0 6.0 7.0 9.0 10.5 14.5
30.0 7.0 8.0 10.0 12.0 17.0
40.0 9.0 10.0 13.0 15.0 21.0
50.0 11.0 12.5 16.0 18.0 25.0
60.0 13.0 14.5 18.0 20.0 28.0
70.0 15.0 16.5 20.0 22.0 31.0
80.0 17.0 19.0 22.0 24.0 34.0
90.0 19.0 21.0 24.0 26.0 37.0
100.0 21.0 23.0 26.0 28.0 40.0
110.0 23.0 25.0 28.0 30.0 43.0
120.0 25.0 27.0 30.0 32.0 46.0
130.0 27.0 29.0 32.0 34.0 49.0
140.0 29.0 31.0 34.0 36.0 52.0
145.0 30.0 32.0 35.0 37.0 54.0
150.0 31.0 33.0 36.0 38.0 55.0
155.0 32.0 34.0 37.0 39.0 56.0
160.0 33.0 35.0 38.0 40.0 57.0
165.0 34.0 36.0 39.0 41.0 59.0

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 Load Calculation & Load Management Case Study

170.0 35.0 37.0 40.0 42.0 60.0

175.0 36.0 38.0 41.0 43.0 61.0
180.0 37.0 39.0 42.0 44.0 62.0
185.0 38.0 40.0 43.0 45.0 63.0
190.0 38.0 40.0 43.0 45.0 65.0
200.0 40.0 42.0 45.0 47.0 97.0
250.0 45.0 50.0 55.0 60.0 70.0

10.3 Section of Associated Equipment

SELECTION OF ASSOCIATED EQUIPMENT

Current (amps) Cable Size in MM
Fuse Rating
rating at Sq. Switch
KVAr Tinned gear
HRC
415V 440V Al. Cu. Cu. rating
(Amp.)
(SWG)
1 1.39 1.31 1.5 1.5 4 33 15
2 2.78 2.62 1.5 1.5 6 32 15
3 4.17 3.94 1.5 1.5 10 29 15
4 5.56 5.25 1.5 1.5 10 26 15
5 6.95 6.56 2.5 2.5 15 24 15
6 8.34 7.87 4.0 2.5 15 23 30
7.5 10.43 9.84 4.0 4.0 20 22 30
10 13.91 13.12 10.0 6.0 25 20 30
12.5 17.39 16.40 10.0 10.0 35 19 63
15 20.86 19.68 16 10.0 50 18 63
20 27.82 26.24 25 16.0 50 18 63
25 34.78 32.80 35 25.0 63 16 100
30 41.74 39.36 50 35.0 80 14 100
40 55.65 52.48 70 50.0 100 13 125
50 69.56 65.61 95 70.0 125 - 160
75 104.3 98.41 185 150.0 200 - 250
100 139.12 131.21 240 240.0 250 - 300

S.S.P.M.’s COE. 59
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10.4 Earthing Details

LIMIT ON EARTH RESISTANCES

Sr.No. Particular E. Resistance
In ohms
1 Large Power Station 0.5
2 Major Sub-Stations 1.0
3 Small Stations 2.0
4 Tower Footing Stations 15.0
5 Distribution 10.0

GALVANISED EARTHING DETAILS

Approx.
G.I. Cond Area MM2 Nominal Dia Approx.
Resistance
Size MM Weight Kg/M
Ohm/M
14 S.W.G. 3.24 2.03 0.026 0.0433
12 S.W.G. 5.48 2.64 0.044 0.02565
10 S.W.G. 8.35 3.26 0.0.67 0.0162
8 S.W.G. 12.97 4.06 0.104 0.01063
4 S.W.G. 27.27 5.89 0.218 0.00505
25×3 MM 75.00 - 0.600 0.0017
32×6 MM 192.00 - 1.536 0.0007
50×6 MM 300.00 - 2.400 0.00033

S.S.P.M.’s COE. 60
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10.5 Conductor Calculation

COPPER AND ALUMINIUM CONDUCTORS

COPPER ALUMINIUM
Cross
section Cross Resistan
Approxima Resistanc
al Sectional ce at
te e at
Area – Area Weight 0 Weight 200C
Swg.No. 20 C
Sq. mm in2 Kg. Km. Kg. Km. Ohm
Ohm Km2
mm2 Km2

1 0.00155 18 8.89 12.86 2.7 30.3

1.5 0.00230 17 13.34 11.91 4.04 20.2
2.5 0.0038 15 22.33 7.144 6.74 12.12
4 0.0062 13 35.56 4.46 10.8 7.575
6 0.0093 11 53.34 2.977 16.2 5.05
10 0.0155 9 88.99 1.786 27 3.03
16 0.0248 7 142.2 1.116 43.2 1.894
25 0.0388 4 222.3 0.714 67.4 1.212
35 0.0543 2 311.2 0.510 94.4 0.866
50 0.078 1.0 444.5 0.357 135 0.606
70 0.108 3.0 622.3 0.255 189 0.433
95 0.147 5.0 844.6 0.188 256 0.319
120 0.186 -- 1067 0.1488 323 0.2525
150 0.233 -- 1334 0.1191 404 0.202
185 0.0286 -- 1645 0.0965 488 0.1638
240 0.372 -- 2134 0.0744 646 0.1263
300 0.465 -- 2677 0.0595 808 0.101
400 0.620 -- 3556 0.0447 1016 0.0758
500 0.780 -- 4445 0.0357 1356 0.0606
625 0.956 -- 5556 0.286 1688 0.0485

S.S.P.M.’s COE. 61
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10.6 Voltage Drop Calculation

An approximate check can be made on voltage drop by means of the following formulae

For d.c. and single - phase a.c. to wire systems

2((? (&(@
1000
For three – Phase a.c. systems

1.732 (  ( ? ( & ( @
1000
Where I = Current in amperes

L = Length of cable run in metals ( One conductor only)

R = Resistance in ohms of one conductor only from table

t = Temperature correction factor

S.S.P.M.’s COE. 62
 Load Calculation & Load Management Case Study

SELECTION CHART
OF MCBs FOR
HOUSEHOLD
APPLIANCES

S.S.P.M.’s COE. 63
 Load Calculation & Load Management Case Study

Appliances Capacity Current Type

Wattage Rating of MCB
MCB Series
Air Conditioner 1Tonne 10 amps. “G”
1.5 Tonne 16 amps. “
2 Tonne 20 amps. “
Refrigeratior 165 1.5” “G”
Litres/400W
285 2 amps. “
Litres/600W
350 4 amps. “
Litres/750W
Cooking range with
Oven cum 4500 Watts 25 amps. “L”
grililer
Oven cum 1750 Watts 10 amps. “
grililer
Oven only 750 Watts 6 amps. “
Hot plate only 2000 Watts 10 amps. “
Room Heater 1000 Watts 6 amps. “
2000 Watts 10 amps. “
Washing 300 Watts 2 amps. “
Machine
-DO- (With 1300Watts 10 amps. “
Heafers)
400 Watts 3 amps. “
Water Heater
(Storage or 1 KW 6 amps. “L”
instantaneous)
2 KW 10 amps. “
3 KW 16 amps. “

S.S.P.M.’s COE. 64
 Load Calculation & Load Management Case Study

6 KW 30 amps. “
Electric Iron 750 Watts 6 amps. “
1250 Watts 7.5” “
Electric Kettle 1500 Watts 10 amps. “L”
Auto Toaster(2 1200 Watts 6 amps. “
Slices)
Mixer/Juicer 300 Watts 1.5 amps. “G”
TV/VCR/Music 200 Watts 1 amps. “L”
System
Vaccum 400 Watts 3 amps. “G”
Cleaner
Photo Copier 1500 Watts 10 amps. “G”
Water Cooler 700 Watts 6 amps. “G”

S.S.P.M.’s COE. 65
 Load Calculation & Load Management Case Study

CURRENT RATINGS (ac)

FOR TWO, THREE & FOUR CORE

650/1100 volts, Armoured or un-Armoured Aluminium Conductor

Cables as per IS : 3961 (PART ll) - 1967

Nominal LAID DIRECT

Area of IN THE GROUND IN DUCTS IN AIR
conductor

3,3 &4 3,3 &4 3,3 &4

mm2
2 CORE 2 CORE 2 CORE
COUR COUR COUR
amps amps amps amps amps amps
1.5 18 16 16 14 16 13
2.5 25 21 21 18 21 18
4 32 28 27 23 27 23
6 40 35 34 30 35 30
10 55 46 45 39 47 40
16 70 60 58 50 59 51
25 90 76 76 63 78 70
35 110 92 92 77 99 86
50 135 110 115 95 125 105
70 160 135 140 115 150 130
95 190 165 170 140 185 155
120 210 185 190 155 210 180
150 240 210 210 175 240 205
185 275 235 240 200 275 240
240 320 275 275 235 325 280
300 355 305 305 260 365 315
400 385 335 345 290 420 375

S.S.P.M.’s COE. 66
 Load Calculation & Load Management Case Study

HOUSEHOLD CABLES

Plain Annealed Copper Conductor Single Core PVC Insulated and

unsheathed

SIZE OF CONDUCTOR Thickness Overall Current

Type Nominal No. and of diameter Rating in
area diameter insulation Amp.
of wires
BSS : Sq. in In. In. In.
2004 .0015 1/.044 .035 .119 5
250 Volts .002 3/.029 0.35 .137 10
.003 3/.036 .035 .153 15
.0045 7/.029 .035 .162 20
.007 7/.036 .040 .193 28
.01 7/.044 .040 .217 36
.0145 7/.052 0.40 .241 43
.0225 7/.064 .040 .277 53

Mm2 Mm mm mm
BSS : 1.0 1/1.13 0.8 2.9 11
6004 1.5 1/1.38 0.8 3.1 14
600 2.5 1/1.78 0.8 3.5 19
Volts 4 7/0.85 0.8 4.3 26
6 7/1.04 0.8 4.9 31
10 7/1.35 0.8 6.2 42

S.S.P.M.’s COE. 67
 Load Calculation & Load Management Case Study

IS CODES AND
STANDARDS

S.S.P.M.’s COE. 68
 Load Calculation & Load Management Case Study

IS 1886 & 11028 Selection and installation and maintenance of transformer

IS 3072 Installation and maintenance of Switchgear

IS 900 Installation and maintenance of Induction motor

IS 4648 Electrical layout in residential buildings

IS 3043 Code of Practice of Earthing

IS 2274 Electrical wiring installation (Voltage exceeding 650 V)

IS 2551 Danger Notice Boards

IS 4064 Normal Duty air break switches and composite units of air break switches

And fuses for voltages not exceeding 1000V

S.S.P.M.’s COE. 69
 Load Calculation & Load Management Case Study

PANEL DESINGNING

S.S.P.M.’s COE. 70
 Load Calculation & Load Management Case Study

13.1 Calculation of MCB

1] GROUND FLOOR:-

1. Class Room I –

P = 1820 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

H 
I =
(.I

I = 8.79 A

Required MCB = 10 A

2. Class Room II –

P = 1820 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

H 
I = (.I

I = 8.79 A

Required MCB = 10 A

3. Class Room III –

P = 1820 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

H 
I =
(.I

S.S.P.M.’s COE. 71
 Load Calculation & Load Management Case Study
I = 8.79 A

Required MCB = 10 A

4. Class Room IV –

P = 1820 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

H 
I =
(.I

I = 8.79 A

Required MCB = 10 A

5. Toilet –

P = 1820 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

H 
I =
(.I

I = 8.79 A

Required MCB = 10 A

6. Store Room –

P = 960 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

I=
I =
(.I

I = 4.63 A

Required MCB = 6 A

S.S.P.M.’s COE. 72
 Load Calculation & Load Management Case Study

7. Seminar Hall 1 –

light Load

P = 1940 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

IJ
I = (.I

I = 9.37 A

Required MCB = 16 A

Power Load

P = 3200 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

 
I = (.I

I = 15.45 A

Required MCB = 16 A

8. Seminar Hall 2 –

Light Load

P = 1940 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

IJ
I =
(.I

I = 9.37 A

Required MCB = 16 A

S.S.P.M.’s COE. 73
 Load Calculation & Load Management Case Study
Power Load

P = 3200 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

 
I = (.I

I = 15.45 A

Required MCB = 16 A

9. Court Yard 1 –

P = 180Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

H
I = (.I

I = 0.87A

Required MCB = 6 A

10. Court Yard 2 –

P = 180Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

H
I =
(.I

I = 0.87A

Required MCB = 6 A

11. Meeting Room 1 –

P = 3360Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

S.S.P.M.’s COE. 74
 Load Calculation & Load Management Case Study

I=
E FG Ø

=
I = (.I

I = 16.23A

Required MCB = 25 A

12. Meeting Room 2 –

P = 1940Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

IJ
I =
(.I

I = 9.37A

Required MCB = 16 A

13. Jr. Trustee Room –

P = 1680Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

IH
I =
(.I

I = 8.11A

Required MCB = 10 A

14. Registrar Room –

P = 1680Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

IH
I =
(.I

I = 8.11A

S.S.P.M.’s COE. 75
 Load Calculation & Load Management Case Study
Required MCB = 10 A

15. Toilet –

P = 240 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

J
I = (.I

I = 1.16 A

Required MCB = 6A

16. Office – I

P = 3440 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

JJ
I = (.I

I = 16.61 A

Required MCB = 25A

Computer load

P = 5000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

*
I =
(.I

I = 24.15 A

Required MCB = 25A

S.S.P.M.’s COE. 76
 Load Calculation & Load Management Case Study
17. Lab. No. 1
A) Light load

P = 1060 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

=
I =
(.I

I = 5.12 A
Required MCB = 6A

B) Power load for (15A p.p.)

P = 3000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I = (.I

I = 14.49 A

Required MCB = 16A

C) Power load for (I.P.) I :-

P = 6500Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

=*
I =
(.I

I = 31.40 A

Required MCB = 32A

D) Power load for (I.P.) II :-

P = 6500Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

S.S.P.M.’s COE. 77
 Load Calculation & Load Management Case Study

I=
E FG Ø

=*
I = (.I

I = 31.40 A

Required MCB = 32A

18. Lab. No. 2

A) Light load

P = 1200 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I = (.I

I = 5.79 A
Required MCB = 6A

B) Power load for (15A p.p.)

P = 3000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I = (.I

I = 14.49 A

Required MCB = 16A

C) Power load for (I.P.) I :-

P = 3000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I = (.I

I = 14.49 A

S.S.P.M.’s COE. 78
 Load Calculation & Load Management Case Study
Required MCB = 16A

D) Power load for (I.P.) II :-

P = 4000Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

J
I = (.I

I = 19.32 A

Required MCB = 25A

19. Lab. No. 3

A) Light load

P = 1060 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

=
I = (.I

I = 5.12 A
Required MCB = 6A

B) Power load for (15A p.p.)

P = 3000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I = (.I

I = 14.49 A

Required MCB = 16A

C) Power load for (I.P.) I :-

P = 3600 Watt , V = 230 V , Cos Ø = 0.90

S.S.P.M.’s COE. 79
 Load Calculation & Load Management Case Study
P = V I Cos Ø

I=
E FG Ø

=
I =
(.I

I = 17.39 A

Required MCB = 25A

20. Lab. No. 4

A) Light load

P = 1060 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

=
I =
(.I

I = 5.12 A
Required MCB = 6A

B) Power load for (I)

P = 2475Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

J)*
I = (.I

I = 11.95 A

Required MCB = 16A

C) Power load for (I.P.) I :-

P = 2475Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

J)*
I = (.I

S.S.P.M.’s COE. 80
 Load Calculation & Load Management Case Study
I = 11.95 A

Required MCB = 16A

21. Principal Cabin -

A) Light load

P = 2400 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

J
I =
(.I

I = 11.59 A
Required MCB = 16A

22. Machine Lab.

A) Light load

P = 2420 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

J 
I =
(.I

I = 11.69A
Required MCB =1 6A

B) Power load

P = 30HP =24920 Watt , V = 440 V , Cos Ø = 0.8

P =√3 V I Cos Ø

I=
√ E FG Ø

JI 
I =
√(JJ(.H

I = 40.87 A

Required MCB by considering future load = 100 A TPN MCCB

23. Toilet –

S.S.P.M.’s COE. 81
 Load Calculation & Load Management Case Study
P = 280 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

H
I = (.I

I = 1.35 A

Required MCB = 6A

24. Machine Lab.

A) Light load + Some I.P. load

P = 4760 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

J)=
I =
(.I

I = 23A
Required MCB =25A

B) I.P. load

P = 5000 Watt , V = 230 V , Cos Ø = 0.9

P = V I Cos Ø

I= E FG Ø

*
I = (.H

I = 24.15 A

Required MCB =25A

25. CS Lab.
A) Light load + Some I.P. load

P = 2940 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

S.S.P.M.’s COE. 82
 Load Calculation & Load Management Case Study

I=
E FG Ø

IJ
I = (.I

I = 14.20A
Required MCB =16A

B) I.P. load

P = 6000 Watt , V = 230 V , Cos Ø = 0.9

P = V I Cos Ø

I=
E FG Ø

=
I =
(.H

I = 28.98 A

Required MCB =32A

26. H.O.D. (Electrical) -

P = 1400 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

J
I =
(.I

I = 6.76A
Required MCB =10A

27. B.E. Class Room -

P = 2140 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

J
I =
(.I

I = 10.33A
Required MCB =10A

28. T.E. Class Room -

S.S.P.M.’s COE. 83
 Load Calculation & Load Management Case Study
P = 2140 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

J
I = (.I

I = 10.33A
Required MCB =10A

29. T.P.O.Room -
P = 680 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

=H
I =
(.I

I = 3.28A
Required MCB =6A

30. Cooler -
P = 1400 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

J
I = (.I

I = 7.24A
Required MCB =10A

31. Spare – (Tube light)

P = 600 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

=
I = (.I

I = 2.89A
Required MCB =6A

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 Load Calculation & Load Management Case Study
Spear – (C.F.L.)
P = 400 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

J
I =
(.I

I = 1.93A
Required MCB = 6A

Spare – (I.P.)
P = 1800 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

H
I = (.I

I = 8.69A
Required MCB = 10A

S.S.P.M.’s COE. 85
 Load Calculation & Load Management Case Study

2] FIRST FLOOR:-

1. Class Room I –

P = 2740 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

)J
I =
(.I

I = 13.23 A

Required MCB = 16A

2. Class Room II –

P = 2740 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

)J
I = (.I

I = 13.23 A

Required MCB = 16A

3. Class Room III –

P = 2740 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

)J
I =
(.I

I = 13.23 A

Required MCB = 16A

S.S.P.M.’s COE. 86
 Load Calculation & Load Management Case Study
4. Class Room IV –

P = 2740 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

)J
I = (.I

I = 13.23 A

Required MCB = 16A

5. Class Room V –

P = 2720 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

) 
I = (.I

I = 13.14 A

Required MCB = 16A

6. Class Room VI –

P = 2720 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

) 
I =
(.I

I = 13.14 A

Required MCB = 16A

7. Lab. No. 1
A) Light load

P = 760 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

S.S.P.M.’s COE. 87
 Load Calculation & Load Management Case Study

I=
E FG Ø

)=
I = (.I

I = 3.67 A
Required MCB = 6A

B) A.C. load

P = 3000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø


I =
(.I

I = 14.49 A

Required MCB = 16A

C) P.C. load - I

P = 6000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

=
I =
(.I

I = 28.98 A

Required MCB = 32A

D) P.C. load - II

P = 6000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

=
I =
(.I

I = 28.98 A

Required MCB = 32A

S.S.P.M.’s COE. 88
 Load Calculation & Load Management Case Study
8. Lab. No. 2
A) Light load

P = 1200Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø


I =
(.I

I = 5.79A
Required MCB = 6A

B) P.C. load - I

P = 6500 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

=*
I = (.I

I = 31.40 A

Required MCB = 32A

C) P.C. load - II

P = 6000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

=
I = (.I

I = 28.98 A

Required MCB = 32A

D) A.C. load

P = 3000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

S.S.P.M.’s COE. 89
 Load Calculation & Load Management Case Study

I=
E FG Ø


I = (.I

I = 14.49 A

Required MCB = 16A

9. Lab. No. 3
A) Light load

P = 920 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

I 
I = (.I

I = 4.44 A
Required MCB = 6A

B) A.C. + Some P.C.load

P = 3000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I = (.I

I = 14.49 A

Required MCB = 16A

C) P.C. load - I

P = 5000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

*
I =
(.I

I = 24.15 A

S.S.P.M.’s COE. 90
 Load Calculation & Load Management Case Study
Required MCB = 25A

D) P.C. load - II

P = 4500 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

J*
I =
(.I

I = 25A

Required MCB = 32A

10. Lab. No. 4

P = 1900 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

I
I = (.I

I = 9.17A
Required MCB = 10A

11. Lab. No. 5

A) Light load

P = 1920Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

I 
I =
(.I

I = 9.27 A
Required MCB = 10A

B) A.C. load

P = 3000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

S.S.P.M.’s COE. 91
 Load Calculation & Load Management Case Study

I=
E FG Ø


I = (.I

I = 14.49 A

Required MCB = 16A

C) P.C. load - I

P = 5000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

*
I =
(.I

I = 24.15 A

Required MCB = 25A

D) P.C. load - II

P = 5000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

*
I = (.I

I = 24.15 A

Required MCB = 25A

E) P.C. load - III

P = 5000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

*
I =
(.I

I = 24.15 A

S.S.P.M.’s COE. 92
 Load Calculation & Load Management Case Study
Required MCB = 25A

12. Lab. No. 6

A) Light load

P = 2000Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø


I =
(.I

I = 9.66A
Required MCB = 10A

B) A.C. load

P = 3000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I =
(.I

I = 14.49 A

Required MCB = 16A

C) P.C. load - I

P = 5000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

*
I =
(.I

I = 24.15 A

Required MCB = 25A

D) P.C. load - II

S.S.P.M.’s COE. 93
 Load Calculation & Load Management Case Study
P = 5000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

*
I = (.I

I = 24.15 A

Required MCB = 25A

E) P.C. load - III

P = 5000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

*
I =
(.I

I = 24.15 A

Required MCB = 25A

13. Toilet -
P = 200Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I =
(.I

I = 0.96A
Required MCB = 6A

14. Class Room VII –

P = 2740 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

)J
I = (.I

S.S.P.M.’s COE. 94
 Load Calculation & Load Management Case Study
I = 13.23 A

Required MCB = 16A

15. Class Room VIII –

P = 2740 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

)J
I =
(.I

I = 13.23 A

Required MCB = 16A

16. Class Room IX –

P = 2740 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

)J
I =
(.I

I = 13.23 A

Required MCB = 16A

17. H.O.D. (Computer)-

P = 1400 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

J
I =
(.I

I = 6.76A
Required MCB = 10A

18. Toilet -
P = 220Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

S.S.P.M.’s COE. 95
 Load Calculation & Load Management Case Study

I=
E FG Ø


I = (.I

I = 1.06A
Required MCB = 6A

19. Cooler -
P = 1500 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

*
I = (.I

I = 7.24A
Required MCB =10A

30. Spear – (Tube light+ C.F.L.)

P = 800 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

H
I =
(.I

I = 3.86A
Required MCB =6A

Spare – (I.P.)
P = 1200 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I =
(.I

I = 5.79A
Required MCB = 6A

S.S.P.M.’s COE. 96
 Load Calculation & Load Management Case Study

3] SECOND FLOOR:-

1. Class Room I –

P = 2800 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

H
I =
(.I

I = 13.52 A

Required MCB = 16A

2. Class Room II –

P = 2680 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

=H
I = (.I

I = 12.94 A

Required MCB = 16A

3. Class Room III –

P = 2740 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

)J
I =
(.I

I = 13.23 A

Required MCB = 16A

S.S.P.M.’s COE. 97
 Load Calculation & Load Management Case Study

4. Class Room IV –

P = 2340 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

J
I = (.I

I = 11.30 A

Required MCB = 16A

5. Class Room V –

P = 2140 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

J
I = (.I

I = 10.33 A

Required MCB = 16A

6. Class Room VI –

P = 2140 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

J
I =
(.I

I = 10.33 A

Required MCB = 16A

7. Class Room VII –

P = 2140 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

S.S.P.M.’s COE. 98
 Load Calculation & Load Management Case Study

I=
E FG Ø

J
I = (.I

I = 10.33 A

Required MCB = 16A

8. Class Room VIII –

P = 2140 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

J
I =
(.I

I = 10.33 A

Required MCB = 16A

9. Toilet –

P = 220 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I =
(.I

I = 1.06 A

Required MCB = 6A

10. Lab. No. 1

A) Light load

P = 1040Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

J
I =
(.I

I = 5.02A
S.S.P.M.’s COE. 99
 Load Calculation & Load Management Case Study
Required MCB = 6A

B) Power load

P = 3500 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

*
I =
(.I

I = 16.90 A

Required MCB = 25A

11. Lab. No. 2

A) Light load

P = 1200Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I = (.I

I = 5.79A
Required MCB = 6A

B) Power load

P = 3600 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

=
I = (.I

I = 17.39 A

Required MCB = 25A

12. Lab. No. 3

A) Light load

S.S.P.M.’s COE. 100

 Load Calculation & Load Management Case Study
P = 1920Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

I 
I = (.I

I = 10A
Required MCB = 10A

B) P.C. load

P = 3500 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

*
I =
(.I

I = 16.90 A

Required MCB = 25A

C) I.P. load - I

P = 4500 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

J*
I =
(.I

I = 21.73 A

Required MCB = 25A

D) I.P. load - II

P = 4500 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

S.S.P.M.’s COE. 101

 Load Calculation & Load Management Case Study
J*
I =
(.I

I = 21.73 A

Required MCB = 25A

13. Lab. No. 4

A) Light load

P = 1960Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

I=
I =
(.I

I = 9.45A
Required MCB = 10A

B) P.C. load + I.P Load

P = 3300 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I =
(.I

I = 15.94 A

Required MCB = 16A

C) I.P. load - I

P = 3300 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I =
(.I

I = 15.94 A

Required MCB = 16A

S.S.P.M.’s COE. 102

 Load Calculation & Load Management Case Study
D) I.P. load - II

P = 3300 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø


I = (.I

I = 15.94 A

Required MCB = 16A

14. Lab. No. 5

P = 3520Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

* 
I = (.I

I = 17A
Required MCB = 25A

15.H.O.D. (Extc.)
P = 1280Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

H
I = (.I

I = 6.18A
Required MCB = 10A

16.Toilet-
P = 400Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø

J
I = (.I

S.S.P.M.’s COE. 103

 Load Calculation & Load Management Case Study
I = 1.93A
Required MCB = 6A

17. Basement -
A) Light load

P = 1480Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I=
E FG Ø

JH
I = (.I

I = 7.14A
Required MCB = 10A, given 25 A

B) I.P. load - I

P = 3000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I =
(.I

I = 14.49 A

Required MCB = 16A

C) I.P. load - II

P = 3000 Watt , V = 230 V , Cos Ø = 0.90

P = V I Cos Ø

I = E FG Ø


I =
(.I

I = 14.49 A , Required MCB = 16A

S.S.P.M.’s COE. 104

 Load Calculation & Load Management Case Study

TOTAL LOAD OF S.S.P.M’S COLLEGE OF ENGINEERING KANKAVLI

1. GROUND FLOOR = 135.22 KW.

2. FIRST FLOOR = 114.44 KW.
3. SECOND FLOOR = 67.60 KW

TOTAL LOAD = 317.26KW

Actual load = Connected load × Diversity factor

Assume , D.F. = 0.5

Actual Load = Connected load × 0.5

= 317.26 KW × 0.5

= 158.63 KW

KL
IL=
√(6(.Ø

*H.=KL
IL=
√(J
*(.I

IL= 245.20 A

S.S.P.M.’s COE. 105

 Load Calculation & Load Management Case Study

 2MN
IT=
OP3PQPR

G = Grouping Factor

A = Ambient Temperature (450) for connection factor =0.78

T = Thermal Insulation factor = 1

S = Semi enclosed factor = 1

J*.  3
IT =
.H=(.)I(
(

IT = 360.91 A
IT = 361 A

S.S.P.M.’s COE. 106

 Load Calculation & Load Management Case Study

13.2 Calculation of Bus bar

Total Current is 361 A Considering 20% future expansion

Hence total current is IT = 433.2 A

So we are selecting Bus bar rating of 500 A with copper plate.

13.3 Calculation of Change over Switch

Total Current is 361 A Considering 20% future expansion

Hence total current is IT = 433.2 A
So we are selecting rating changeover switch of 500 A .

13.4 Selecting of TPN MCCB

1. For MSEB Supply

total current is IT = 433.2 A So we are selecting TPN MCCB of 500 A
2. For D.G. Supply
Rating of generator is 100 KVA
Total Current =KVA/CosØ =100/0.8 = 125A
So we are selecting TPN MCCB of 200 A .

S.S.P.M.’s COE. 107

 Load Calculation & Load Management Case Study

DISTRIBUTION
DIAGRAM

S.S.P.M.’s COE. 108

 Load Calculation & Load Management Case Study

CALCULATION OF
TRANSFORMER

S.S.P.M.’s COE. 109

 Load Calculation & Load Management Case Study

Calculation of transformer
KVA rating :-
:;(2.9.(S.9.
KVA =
T(.9.

Assume

L.F. = 0.8, D.F. = 0.5, η = 0.8 , P.F. = 0.85


.J(.H(.*.
KVA =
.H(.H*

= 186.62 KVA

20% of future expansion

Select transformer rating is = 200 KVA

Transformer rating is = 200 KVA

S.S.P.M.’s COE. 110

 Load Calculation & Load Management Case Study

CALCULATION OF
CABLE SIZE

S.S.P.M.’s COE. 111

 Load Calculation & Load Management Case Study

Calculation of cable
16.1) Select the cable size from transformer secondary to panel
3.7UM6 6MN
IL=
√((,9.

Actual load = Connected load × D.F.

= 317.26 × 0.5

= 158.63

*H.=KL
IL=
√(J
*(.I

IL = 245.20 A

I (Overload) = IL (as load is static )

So IL = 245.20A

Then for that select cable size is a 240 mm2 pvc insulated copper conductor cable

Cable size is a 240 mm2

16.2) Voltage Drop

Voltage drop in cable = vtg drop /A/M×IT×l
= 0.2 m × 361 ×55 mtr
= 3.971 V
Permissible Voltage drop = 5% × Supply Vtg.
= 0.05 × 415
= 20.75 V
So Cable design is correct

[ permissible voltage drop > Calculated voltage drop ]

S.S.P.M.’s COE. 112

 Load Calculation & Load Management Case Study

CONCLUSION

S.S.P.M.’s COE. 113

 Load Calculation & Load Management Case Study
The present production of electricity is not even meeting the regular load requirements of the
customers. So electrical authorities will be forced to go for the demand side Load Management.
Hence the norms for the poor usage and efficiency at which the apparatus are working, is going to
very crucial in the years to come.

In next few years there will be heavy penalty for the inefficient usage of electrical energy , so
the cost of electricity will be very high. Hence it is suggested to carry out Load Calculation and
Management for every organization.

S.S.P.M.’s COE. 114

 Load Calculation & Load Management Case Study

BIBLIOGRAPHY

S.S.P.M.’s COE. 115

 Load Calculation & Load Management Case Study

References

 Roy S. “Energy Conservation through compact fluorescence lamps”

electrical India.

 “ Energy Audit A new mantra for Energy Conservation ” , Electrical

India.

 Electrical Contractor Association of Maharashtra Diary 2009

 Designing with light, a lighting hand book , lighting systems 2002 -

Valia A.

 Lamps & Lighting, Cayless M. A. & Marsden A. M.

S.S.P.M.’s COE. 116