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Code Calculations: James Stallcup JR
Code Calculations: James Stallcup JR
Code Calculations: James Stallcup JR
Industrial Calculations: Feeder Loads -- Part 3 Now it's time to use what
we've learned in this column over the last several issues and calculate the
service load for feeders No. 1 through No. 6 in our hypothetical industrial
plant. See the April and May 2001 articles for amperage values of feeders
No. 1 through No. 6. Refer to the Figure for a one-line diagram of the
electrical equipment. When computing
James Stallcup Jr.
Now it's time to use what we've learned in this column over the last several issues and
calculate the service load for feeders No. 1 through No. 6 in our hypothetical industrial
plant. See the April and May 2001 articles for amperage values of feeders No. 1 through
No. 6. Refer to the Figure for a one-line diagram of the electrical equipment.
When computing the load for an existing electrical system or when designing an entirely
new system an important tool is a good, up-to-date line diagram of the system.
Refer to the following Code sections when performing your calculations: Secs. 230-42(a)
(1), 430-24, and 440-34.
Step 1: Calculate the amps of each feeder and the total load [Sec. 220-2(a)].
This involves adding up the individual loads each feeder must supply. Determine these
loads by looking at specification sheets and estimating receptacle loads. From previous
parts of this series, we have the following values:
Step 2: Calculate kVA of feeders 1, 3, 5, and 6, based on supply voltage and load.
To do this, multiply the current by the voltage. Then, multiply that answer by the square
root of three because this is a 3-phase system now you have your VA. Divide your
answer by 1000 so you can express the value in kVA.
Feeder No. 1.
kVA=684.65A x 480V x 1.732/1000
kVA=569.19kVA
Feeder No. 3.
kVA=534.525A x 208V x 1.732/1000
kVA=192.57kVA
Feeder No. 5.
kVA=588.05A x 480V x 1.732/1000
kVA=488.88kVA
Feeder No. 6.
kVA=405A x 4160V x 1.732/1000
kVA=2918.07kVA
Step 3: Calculate amps of each feeder, based on supply voltage and load.
To do this, convert kVA to VA by multiplying your kVA values by 1000. Because it's 3-
phase, next multiply your voltage by the square root of three. Divide your first answer by
your second answer, and you have your current. Be sure to round decimals up, not down
no matter how small the “extra” is.
Feeder No. 1.
I=kVA x 1000/(V x 1.732)
I=569.19kVA x 1000/(13,800V x 1.732)
I=23.82A
Feeder No. 2.
Amps at 13,800V=27.88A
Feeder No. 3.
I=kVA x 1000/(V x 1.732)
I=192.57kVA x 1000/(13,800V x 1.732)
I=8.06A
Feeder No. 4.
Amps at 13,800V=15A
Feeder No. 5.
I=kVA x 1000÷(V x 1.732)
I=488.88kVA x 1000/(13,800V x 1.732)
I=20.46A
Feeder No. 6.
I=kVA x 1000/(V x 1.732)
I=2918.07kVA x 1000/(13,800V x 1.732)
I=122.09A
Solution: Summing the individual amps for each feeder yields a total amperage of
217.31A.
Current of 217.31A at 13.8kV requires No. 4 cu., per Table 310-77. Note, we are not using
Table 310-16 because we are dealing with MV.
Select the transformer based on the available standard size, the amount of loading you
want on the transformer (for example, 60% to 80%), planned additional load, and other
engineering factors. In our example, let's assume this facility plans for a load decrease in
the future, and you are going to load your transformer close to 100%. Such a scenario
can happen when a company retools for more efficient production processes or changes
its focus entirely.
Step 2: Select the transformer. Based on the Code, you need a transformer bank that can
handle 5194.06kVA at 13.8kV.
You'll need this information to size your main switch and breaker, as well as calculate
your fault current.
AFC=FLA of transformer/Z
AFC=217.31A/.02
AFC=10,865.5A
Before you can order switchgear, you need to determine what size breakers you will
need for each feeder. You also need to determine conductor ampacities. Remember, you
must select conductors rated for MV application.
The OCPD for the panelboard will be 700A. Why would the breaker not be smaller than
684.65A? Remember, you are sizing your breaker for the load the circuit must handle.
Size your conductor large enough to handle the current the breaker will allow. If you
remember that the breaker defines the circuit, you will find it easy to keep this straight.
Use three No. 4/0 THWN cu. conductors per phase (parallel conductors) for the
panelboard, based on Table 310-77.
The OCPD for the switchgear will be 30A (based on calculated load) or 50A (based on
conductors). As shown in the April issue, the conductors for the switchgear will be three
No. 6 cu. conductors per phase (parallel conductors) based on Table 310-77, which
shows No. 6 to be the minimum size for 5001V to 35kV.
The OCPD for the primary of the 208/120V transformer will be 50A. This transformer
has a 15:1 winding ratio, and 1/15 of the secondary current is 35.5A. Table 310-77
requires No. 6 cu. conductors for the primary of the transformer. If you were sizing the
conductors on the secondary side of this transformer, you would refer to Table 310-16
(because of the voltage level).
The OCPD for the future load will be 15A. Conductors for the future load will be No. 6
cu., based on Table 310-77.
The total load for the feeder is 405A. The OCPD for the secondary connection will also
be 405A. You could pull two 4/0 THWN cu. conductors in parallel to supply this load,
per Table 310-16.
Lessons learned
Always develop a one-line diagram when calculating feeder loads. This will help you
clearly see the distribution system and avoid calculation errors. If you are using
engineering software or even a spreadsheet to do your calculations, this step will help
you avoid the “garbage in/garbage out” problem. You must work methodically, first
determining your loads and then determining what size transformers you need to supply
them. Size your overcurrent protection so you can run your loads, and size your
conductors large enough to handle the current load demand.