Introduction

The electrical load schedule is an estimate of the instantaneous electrical loads

operating in a facility, in terms of active, reactive and apparent power (measured in
kW, kVAR and kVA respectively). The load schedule is usually categorized by
switchboard or occasionally by sub-facility / area.

Why do the calculation?

Preparing the load schedule is one of the earliest tasks of that needs to be done as
it is essentially a pre-requisite for some of the key electrical design activities (such
as equipment sizing and power system studies).

When to do the calculation?

The electrical load schedule can typically be started with a preliminary key single
line diagram (or at least an idea of the main voltage levels in the system) and any
preliminary details of process / building/ facility loads. It is recommended that the
load schedule is started as soon as practically possible.

Calculation methodology:
There are no standards governing load schedules and therefore this calculation is
based on generally accepted industry practice. The following methodology assumes
that the load schedule is being created for the first time and is also biased towards
industrial plants. The basic steps for creating a load schedule are:

Step 1: Collect a list of the expected loads in the facility

Step 2: For each load, collect the electrical parameters, e.g. nominal /
absorbed ratings, power factor, efficiency, etc
Step 3: Classify each of the loads in terms of switchboard location, load duty
and load criticality
Step 4: For each load, calculate the expected consumed load
Step 5: For each switchboard and the overall system, calculate operating,
peak and design load

Step 1: Collect list of loads

The first step is to gather a list of all the electrical loads that will be supplied by the
power system affected by the load schedule. There are generally two types of loads
that need to be collected:

Process loads are the loads that are directly relevant to the facility. In
factories and industrial plants, process loads are the motors, heaters,
compressors, conveyors, etc that form the main business of the plant.
Process loads can normally be found on either Mechanical Equipment Lists or
Process and Instrumentation Diagrams (P&IDs).

Non-process loads - are the auxiliary loads that are necessary to run the
facility, e.g. lighting, HVAC, utility systems (power and water), DCS / PLC
control systems, fire safety systems, etc. These loads are usually taken from
a number of sources, for example HVAC engineers, instruments, telecoms
and control systems engineers, safety engineers, etc. Some loads such as
lighting, UPS, power generation auxiliaries, etc need to be estimated by the
electrical engineer.

Step 2: Collect electrical load parameters

A number of electrical load parameters are necessary to construct the load
schedule:

Rated power is the full load or nameplate rating of the load and represents
the maximum continuous power output of the load. For motor loads, the
rated power corresponds to the standard motor size (e.g. distribution boards,
package equipment, etc), the rated power is typically the maximum power
output of the item (i.e with all its sub-loads in service).
Absorbed power is the expected power that will be drawn by the load. Most
loads will not operate at its rated capacity, but at a lower point. For example,
absorbed motor loads are based on the mechanical power input to the shaft
of the driven equipment at its duty point. The motor is typically sized so that
the rated capacity of the motor exceeds the expected absorbed load by some
conservative design margin. Where information regarding the absorbed loads
is not available, then a load factor of between 0.8 and 0.9 is normally applied.
Power factor of the load is necessary to determine the reactive components
of the load schedule. Normally the load power factor at full load is used, but
the power factor at the duty point can also be used for increased accuracy.
Where power factors are not readily available, then estimates can be used
(typically 0.85 for motor loads >7.5kW, 1.0 for heater loads and 0.8 for all
other loads).
Efficiency accounts for the losses incurred when converting electrical energy
to mechanical energy (or whatever type of energy the load outputs). Some of
the electrical power drawn by the load is lost, usually in the form of heat to
the ambient environment. Where information regarding efficiencies is not
available, then estimates of between 0.8 and1 can be used (typically 0.85 or
0.9 is used when efficiencies are unknown).

Step 3: Classify the loads

Once the loads have been identified, they need to be classified accordingly:

Voltage level
What voltage level and which switchboard should the load be located? Large loads
may need to be on MV or HV switchboards depending on the size of the load and

how many voltage levels are available. Typically, loads <150kW tend to be on the LV
system (400V 690V), loads between 150kW and 10MW tend to be on an
intermediate MV system (3.3kV 6.6kV) where available and loads >10MW are
usually on the HV distribution system (11kV 33kV). Some consideration should
also be made for grouping the loads on a switchboard in terms of sub-facilities,
areas or sub-systems (e.g. a switchboard for the compression train sub-system or
the drying area).

Load duty
Loads are classified according to their duty as continuous, intermittent and standby
loads:
1) Continuous loads are those that normally operate continuously over a 24
hour period, e.g process loads, control systems, lighting and small power
distribution boards, UPS systems, etc
2) Intermittent loads that only operate a fraction of a 24 hour period, e.g.
intermittent pumps and process loads, automatic doors and gates, etc
3) Standby loads are those that are on standby or rarely operate under normal
conditions, e.g. standby loads, emergency systems, etc
Note that for redundant loads (e.g. 2X100% duty / standby motors), one is usually
classified as continuous and the other classified as standby. This if purely for the
purposes of the load schedule and does not reflect the actual operating conditions
of the loads, i.e. both redundant loads will be equally used even though one is
classified as a standby load.

Load criticality
Loads are typically classified as either normal, essential and critical:
1) Normal loads are those that run under normal operating conditions, e.g. main
process loads, normal lighting and small power, ordinary office and workshop
loads, etc
2) Essential loads are those necessary under emergency conditions; when the
main power supply is disconnected and the system is being supported by an
emergency generator, e.g. emergency lighting, key process loads that operate
during emergency conditions, fire and safety systems, etc
3) Critical are those critical for the operation of safety systems and for facilitating
or assisting evacuation from the plant and would normally be supplied from a
UPS or battery system, e.g. safety-critical shutdown systems, escape lighting,
etc Step 4: Calculate consumed load
The consumed load is the quantity of electrical power that the load is expected to
consume. For each load, calculate the consumed active and reactive loading,
derived as follows:

Pl=

Pabs

Ql=Pl

1
1
cos 2

Where Pl is the consumed active load (kW)

Ql is the consumed reactive load (kVAr)
Pabs is the absorbed load (kW)
is the efficiency (pu)
Cos is the load power factor (pu)
Notice that the loads have been categorized into three columns depending on their
load duty (continuous, intermittent or standby). This is done in order to make it
visually easier to see the load duty and more importantly, to make it easier to sum
the loads according to their duty (e.g. sum of all continuous loads), which is
necessary to calculate the operating, peak and design loads.

Step 5: Calculating operating, peak and design loads

Many organizations / clients have their own distinct method for calculating
operating, peak and design loads, but a generic method is presented as follows:

Operating load
The operating load is the expected load during normal operation. The operating load
is calculated as follows:

OL = Lc + 0.5 X Li
Where LO is the operating load (kW or kVAr)
Lc is the sum of all continuous loads (kW or kVAr)
Li is the sum of all intermittent loads (kW or kVAr)

Peak load
The peak load is the expected maximum load during normal operation. Peak loading
is typically infrequent and of short duration, occurring when stand by loads are
operated (e.g. for changeover of redundant machines, testing of safety equipment,
etc). The peak load is calculated as the larger of either:

PL = Lc + 0.5 X Li + 0.1X Ls
or

PL = Lc + 0.5 X Li + 0.1X Lslmax

Where PL is the peak load (kW or kVAr)
Lc is the sum of all continuous loads (kW or kVAr)
Li is the sum of all intermittent loads (kW or kVAr)
Ls is the sum of all standby loads (kW or kVAr)
Lslmax is the largest standby load (kW or kVAr)

Design Load
The design load is the load to be used for the design for equipment sizing, electrical
studies, etc. The design load is generally calculated as the larger of either:

DL = 1.1 X OL+ 0.1X Ls

or

DL = 1.1 X OL+ 0.1X Lslmax

Where DL is the design load (kW or kVAr)
OL is the operating load (kW or kVAr)
Ls is the sum of all standby loads (kW or kVAr)
Lslmax is the largest standby load (kW or kVAr)
The design load includes a margin for any errors in load estimation, load growth or
the addition of unforeseen loads that may appear after the design phase. The load
schedule is thus more conservative and robust to errors. On the other hand
however, equipment if often over-sized as a result. Sometimes the design load is
calculated and the peak load is used for design purpose.
Worked Example

Step 1: Collect list of loads

Consider a small facility with the following loads identified:

2
2
1
2
1
1
1
1

x
x
x
x
x
x
x
x

100% vapor recovery compressors (process)

100% recirculation pumps (process)
100% sump pump (process)
50% firewater pumps (safety)
100% HVAC unit (HVAC)
100% AC UPS system (electrical)
normal lighting distribution board (electrical)
essential lighting distribution board (electrical)

Step 2: Collect electrical load parameters

The following electrical load parameters were collected for the loads identified in
step 1:

Abs.
Load

Rated
Load

PF

Eff.

750kW

800kW

0.87

0.95

750kW

800kW

0.87

0.95

Recirculation pump A

31 kW

37kW

0.83

0.86

Recirculation pump B

31 kW

37kW

0.83

0.86

Sump pump

9 kW

11 kW

0.81

0.83

Firewater pump A

65 kW

75 kW

0.88

0.88

Firewater pump B

65 kW

75 kW

0.88

0.88

HVAC unit

80 kW

90 kW

0.85

0.9

AC UPS system

9 kW

12 kW

0.85

0.9

7 kW

10 kW

0.8

0.9

4 kW

5 kW

0.8

0.9

Load Description
Vapor recovery compressor
A
Vapor recovery compressor
B

Normal lighting distribution

board
Essential lighting distribution
board

Step 3: Classify the loads

Suppose we have two voltage levels, 6.6kV and 415V. The loads can be classified as
follows:
Load Description

Rated
Load

Voltage

Duty

Criticalit
y

Vapor recovery compressor

A
Vapor recovery compressor
B

800kW

6.6kV

Continuo
us

Normal

800kW

6.6kV

standby

Normal

Recirculation pump A

37kW

415V

Continuo
us

Normal

Recirculation pump B

37kW

415V

standby

Normal

Sump pump

11 kW

415V

intermitte
nt

Normal

Firewater pump A

75 kW

415V

standby

Essential

Firewater pump B

75 kW

415V

standby

Essential

HVAC unit

90 kW

415V

AC UPS system

12 kW

415V

10 kW

415V

5 kW

415V

Normal lighting distribution

board
Essential lighting distribution
board

Continuo
us
Continuo
us
Continuo
us
Continuo
us

Normal
Critical
Normal
Essential

Step 4: Calculate consumed load

Calculating consumed loads for each of the loads in this example gives:
Load
Description

Abs
Load

Vapor recovery
compressor A
Vapor recovery
compressor B
Recirculation
pump A
Recirculation
pump B

750k
W
750k
W
31
kW
31
kW

Sump pump

9 kW

Firewater
pump A
Firewater
pump B

65
kW
65
kW
80
kW
9 kW

HVAC unit
AC UPS system

PF
0.8
7
0.8
7
0.8
3
0.8
3
0.8
1
0.8
8
0.8
8
0.8
5
0.8

Eff
.
0.9
5
0.9
5
0.8
6
0.8
6
0.8
3
0.8
8
0.8
8

Continuous
P
Q
(kW) (kVAr)
789.5

36.0

Intermittent
P
Q
(kW) (kVAr)

Standby
P
Q
(kW) (kVAr)

447.5
789.5

447.5

36.0

24.2

73.9

39.9

73.9

39.9

24.2

10.84

0.9

88.9

55.1

0.9

10.0

6.2

7.9

5
Normal
lighting
distribution
board
Essential
lighting
distribution
board

7 kW

0.8

0.9

7.8

5.8

4 kW

0.8

0.9

4.4

3.3

1006.
6

542.0

SUM TOTAL

10.84

7.9

973.3

551.4

Step 5: Calculate operating, peak and design loads

The operating, peak and design loads are calculated as follows:
Sum of continuous loads
50% x sum of intermittent
loads
10% x sum of standby loads
Largest standby load
Operating load
Peak load
Design load

P (kW)
1006.6
5.4

Q (kVAr)
542.0
4.0

97.3
789.5
1012.0
1801.5
1902.7

55.1
447.4
546.0
993.4
1047.9

Normally you would separate the loads by switchboard and calculate operating,
peak and design loads for each switchboard and one for the overall system.
However for the sake of simplicity, the loads in this example are all lumped together
and only one set of operating, peak and design loads are calculated.

Operating Scenarios
It may be necessary to construct load schedules for different operating scenarios.
For example, in order to size an emergency diesel generator, it would be necessary
to construct a load schedule for emergency scenarios. The classification of the loads
by criticality will help in constructing alternative scenarios, especially those that use
alternative power sources.