1.
3 Load Calculation
1.3.1 Purpose and Approach
This section determines the factory’s connected load, estimated peak demand, apparent
power, reactive power requirement, and the preliminary sizing of the substation
transformer and power-factor correction equipment. Calculations follow standard power-
engineering practice: list connected loads, apply appropriate load/demand factors,
compute active demand (P), apparent power (S), reactive power (Q), and required
capacitor kvar to meet the target power factor. Equations are presented symbolically and
then evaluated using assumed data; replace assumed values with measured figures where
available.
1.3.2 Load Summary (Assumptions and Table)
Replace assumed values with measured or provided data if available.
Load group Connected load (kW) Notes
Motors & production 1200 Heavy motor loads,
equipment conveyors, VFDs
Lighting 300 Plant lighting
Office & auxiliaries 100 HVAC, offices, small loads
Total connected load 1600 Sum of above
Assumptions:
• Combined load factor (LF) = 0.75.
• Initial (uncompensated) power factor pf_initial = 0.85.
• System frequency f = 50 Hz.
1.3.3 Step-by-step Calculations
(1) Peak active demand P
Symbolic expression:
P = P_connected × LF
Substitution:
P = 1600 kW × 0.75 = 1200.00 kW
(2) Apparent power S
Symbolic expression:
S = P / pf_initial
Substitution:
S = 1200.00 kW / 0.85 = 1411.764705882353 kVA ≈ 1411.76 kVA
(3) Initial reactive power Q_initial
Symbolic expression:
Q = √(S^2 − P^2)
Derivation steps:
Compute S^2 = (1411.764705882353)^2 = 1,993,388.429 (kVA)^2
Compute P^2 = (1200.00)^2 = 1,440,000 (kW)^2
Substitution:
Q_initial = √(1,993,388.429 − 1,440,000) = √(553,388.429) = 743.693 kvar
(4) Reactive power at target power factor (pf_target = 0.90)
Symbolic expressions:
θ_target = arccos(pf_target)
tanθ_target = tan(arccos(pf_target))
Q_target = P × tanθ_target
Numerical substitution:
arccos(0.90) ≈ 25.842°; tan(25.842°) ≈ 0.484322
Q_target = 1200.00 × 0.484322 = 581.187 kvar
(5) Required capacitor kvar
Symbolic expression:
Q_capacitor = Q_initial − Q_target
Numerical substitution:
Q_capacitor = 743.693 − 581.187 = 162.506 kvar
Recommended practical capacitor selection: staged banks totaling 200 kvar (e.g., 3 × 67
kvar steps or 2 ×100 kvar) to provide margin and allow automatic switching.
(6) Preliminary transformer sizing
Symbolic expression:
Choose transformer rating S_tr ≥ S. Consider standard sizes and margin for inrush and future
growth.
Numerical recommendation:
Selected transformer = 1500 kVA (10 kV / 0.4 kV).
Utilization = S / S_tr × 100% = 1411.76 / 1500 × 100% ≈ 94.12%
Considerations: use larger transformer (e.g., 2000 kVA) or two-parallel transformers
(1000 + 1000 kVA) for redundancy and inrush margin.
1.3.4 Notes & Engineering Considerations
• Staged compensation using switched capacitor banks is recommended to avoid
overcompensation at light load and to provide flexibility. Use automatic PF controllers
with time-delay to prevent rapid switching.
• Presence of VFDs and rectifiers increases harmonic currents. Capacitor selection must
consider resonance; detuned passive filters (e.g., with 4–7% reactor) or active filters
(APF) are recommended if harmonic levels are significant.
• Transformer K-factor: if significant non-linear loads exist, specify a K-rated
transformer or derate a standard transformer for harmonic heating.
• Verification: update all calculations with measured profiles and perform steady-state
and harmonic simulations to confirm sizing and finalize equipment selection.