EPS LLC

ELECTRICAL
LOAD ESTIMATION
NATIONAL
ELECTRICAL CODE
 INTRODUCTION TO LOAD ESTIMATION
AND NEC COMPLIANCE

Course Description
This course provides in-depth training on electrical load estimation in
accordance with the National Electrical Code (NEC). The course covers the
fundamentals of load calculations, including residential, commercial, and
industrial applications, and provides practical skills for determining service
sizing, branch circuits, and feeder requirements.

Overview of the National Electrical

Code (NEC)
The National Electrical Code (NEC) is the standard for electrical safety in
residential, commercial, and industrial installations. It provides guidelines on
the design, installation, and inspection of electrical systems, ensuring safety
and proper operation.
For load estimation, Article 220 of the NEC is the most relevant. It covers:
General Requirements for calculating electrical loads.
Specific methods for residential, commercial, and industrial installations.
Service entrance, feeder, and branch circuit load calculations.
Understanding these NEC requirements is critical to ensure that all electrical
installations are safe, code-compliant, and capable of handling the expected
electrical loads.
1
BASIC CONCEPTS OF
LOAD CALCULATION
Electrical load estimation determines the amount of electrical power required for an
installation to operate safely and effectively. These calculations ensure that the electrical
system is sized correctly for the expected load, avoiding overloading and ensuring efficient
energy use.
Key terms to know:
Voltage, Current, and Power.
Power formula:
P= V×I
Where:
P is power in watts,
V is voltage in volts,
I is current in amperes.
Power Factor (PF): The ratio of real power (kW) to apparent power (kVA). A power factor less
than 1 means some power is lost due to inefficiencies (often in motors and inductive loads).
Load types:
Real power (kW): Power that does useful work, such as heating or lighting.
Apparent power (kVA): The combination of real power and reactive power (inefficiencies
like inductance).
Continuous vs. Non-continuous loads:
Continuous loads run for 3 hours or more (e.g., lighting in an office).
Non-continuous loads operate for shorter periods.
For safety, the NEC requires that continuous loads be calculated at 125% of the load current.
IMPORTANCE OF ACCURATE
LOAD ESTIMATION
Accurate load estimation is crucial for several reasons:
1. Preventing overloads: Overloaded circuits can lead to overheating, fires, and damage to
electrical equipment.
2. Sizing electrical components: Correct load calculations ensure that conductors, breakers,
transformers, and other equipment are appropriately sized.
3. Energy efficiency: Proper load estimation helps avoid waste by ensuring that the system
operates at optimal capacity.
4. Compliance with the NEC: Load estimations must align with NEC standards to pass
inspections and avoid costly rework.
NEC ARTICLES RELATED
TO LOAD CALCULATIONS
Several key sections of the NEC are directly related to load calculations:
Article 220 – Load Calculations:
Covers general provisions, the method of determining loads, and special conditions.
Contains rules for calculating branch circuits, feeders, and service entrances in
residential, commercial, and industrial settings.
Article 210 – Branch Circuits:
Specifies load limitations for branch circuits and the placement of outlets.
Article 230 – Service Entrances:
Focuses on sizing and protecting service entrance conductors based on calculated load
requirements.
Article 430 – Motors:
Provides specific rules for calculating loads for motors and determining conductor and
breaker sizing.
Article 240 – Overcurrent Protection:
Relates to the protection of circuits from excessive current due to overloads.
LOAD CALCULATION
EXAMPLE
Basic Residential Load Estimation
A basic example of a load estimation in a residential scenario can be a calculation of general
lighting and appliance loads.
1. General Lighting Load:
2. According to NEC 220.12, the general lighting load in a dwelling is calculated as 3 volt-
amperes (VA) per square foot of the dwelling’s floor area. For a home with 1,200 sq. ft., the
calculation would be:
3. 1,200 sq. ft.×3 VA/sq. ft.=3,600 VA
LOAD CALCULATION
EXAMPLE
4. Small Appliance Circuit Load:
NEC 220.52(A) requires at least two 20-amp small-appliance branch circuits. For each
circuit, the load is calculated at 1,500 VA per circuit. Therefore, for two circuits:
1,500 VA×2=3,000 VA
5. Laundry Circuit Load:
According to NEC 220.52(B), a 1,500 VA load is assigned to the laundry circuit.
The total calculated load so far for this example would be:
3,600 VA (lighting)+3,000 VA (small appliances)+1,500 VA (laundry)=8,100 VA
Converting this to amperes (A) for a 220/380V three phase system:
Total current=8,100 VA /(1.73* 380 V)=12.32 A
This is the basic total load for lighting and small appliances in a 1,200 sq. ft. home. Further
steps would involve calculating additional loads for HVAC, fixed appliances, and other large
equipment.
RESIDENTIAL LOAD
CALCULATIONS
Objective:
In this module, participants will learn the specific steps for calculating electrical loads in
residential settings, following NEC Article 220. Topics include general lighting loads, small-
appliance loads, fixed appliances, heating, air conditioning, and optional methods for load
calculation. By the end of this module, participants will be able to perform accurate residential
load calculations that comply with NEC requirements.
STEP-BY-STEP GUIDE FOR
STANDARD RESIDENTIAL
LOAD CALCULATION
Step 1: General Lighting and Receptacle Load Calculation
According to NEC 220.12, the general lighting load for residential occupancies is calculated
based on the total floor area of the dwelling. The code mandates the following demand factor
for lighting loads:
3 VA per square foot of living space for general lighting and receptacle outlets.
Example: For a 1,500 square foot home:
1,500 sq. ft.×3 VA/sq. ft.=4,500 VA
This is the total general lighting load for the home.

Step 2: Small Appliance Branch Circuit Load

As per NEC 220.52(A), at least two small-appliance branch circuits must be provided for
kitchens, dining areas, and pantry areas. Each of these circuits is rated at 1,500 VA.
For two small-appliance circuits:
1,500 VA×2=3,000 VA
These circuits provide power to outlets in kitchens and dining areas, where high-power
appliances such as microwaves and coffee makers are typically used.
STEP-BY-STEP GUIDE FOR
STANDARD RESIDENTIAL
LOAD CALCULATION
Step 3: Laundry Circuit Load
According to NEC 220.52(B), a laundry branch circuit must be rated at 1,500 VA. This circuit
serves laundry equipment such as washing machines.
1,500 VA (laundry circuit)
Step 4: Fixed Appliance Loads
The NEC requires specific loads to be accounted for any fixed (permanently installed)
appliances in the home. These appliances can include:
Dishwashers.
Garbage disposals.
Water heaters.
Electric ranges and ovens.
Each fixed appliance is rated at 100% of its nameplate rating in VA.
Example: If a home has a 4,500-watt electric range and a 4,000-watt water heater, the load for
these appliances would be:
4,500 W (range)+4,000 W (water heater)=8,500 VA
If there are more fixed appliances, their VA ratings are added to this total.
STEP-BY-STEP GUIDE FOR
STANDARD RESIDENTIAL
LOAD CALCULATION
Step 5: Heating and Air Conditioning Loads
For heating and cooling, the NEC requires that you include the larger of the following two loads:
1. The total connected load for space heating equipment (electric furnaces, baseboard
heaters, etc.).
2. The total connected load for air conditioning (central AC units, heat pumps).
If a home has both heating and cooling systems, calculate both and include the higher of the
two in your total load estimation.
Example:
Heating load: 6,000 watts.
Cooling load: 4,000 watts.
The heating load is higher, so you would use 6,000 watts in your calculation.
STEP-BY-STEP GUIDE FOR
STANDARD RESIDENTIAL LOAD
CALCULATION
Step 6: Application of Demand Factors
Once you have calculated the individual loads, you apply demand factors as specified by the
NEC. Demand factors reduce the total connected load based on the assumption that not all
appliances and lights will be used simultaneously.
According to NEC 220.42, the demand factors for general lighting and small appliance loads
are as follows:
100% for the first 3,000 VA.
35% for any amount over 3,000 VA.
Example: For a total calculated load of 9,000 VA (from general lighting, small-appliance, and
laundry circuits):
The first 3,000 VA is taken at 100%.
The remaining 9,000 VA - 3,000 VA = 6,000 VA is taken at 35%:
3,000 VA+(6,000 VA×0.35)=3,000 VA+ 2,100VA=5,100 VA
So, the adjusted general lighting and small-appliance load is 5,100 VA.
STEP-BY-STEP GUIDE FOR
STANDARD RESIDENTIAL LOAD
CALCULATION
Step 7: Total Load Calculation
Finally, the total residential load is calculated by adding the individual adjusted loads from all
the previous steps. Here's how to sum the calculated loads:
Total load = Adjusted general lighting and receptacle load + Fixed appliance load + HVAC load
Example of a total load calculation for a 1,500 sq. ft. home:
1. General lighting and receptacles: 5,100 VA.
2. Fixed appliances: 8,500 VA (from electric range and water heater).
3. HVAC load: 6,000 VA (from space heating, as it was the larger load).
Total load=5,100 VA + 8,500 VA + 6,000 VA = 19,600 VA
To convert this to amperes for a 230/380V three phase system:
Amps = 19,600 VA/(1.73*380 V) = 29.81 A
In this example, the home would need a service capable of handling at least 29.81 amps.
OPTIONAL METHOD FOR DWELLING
UNIT LOAD CALCULATION
The optional method (NEC 220.82) simplifies load calculations, particularly for larger homes.
This method can be used if the calculated load exceeds 100 amps
OPTIONAL METHOD FOR
DWELLING UNIT LOAD
CALCULATION
The key steps in the optional method include:
1. Calculate general loads (lighting, receptacles, and appliances) using a lower demand
factor:
100% of the first 10 kVA.
40% of any amount over 10 kVA.
2. Apply separate demand factors to the HVAC loads:
Apply 100% to the larger of either the heating or air conditioning load.
The optional method allows for a smaller service size, particularly in larger homes where some
of the loads are not continuously in use.
SMALL HOME

Practical Example: Complete Load Calculation for a Small Home

Let’s calculate the total load for a 1,200 sq. ft. home with the following:
General lighting and receptacle load: 3 VA per sq. ft. = 3,600 VA.
Two small-appliance circuits: 3,000 VA.
One laundry circuit: 1,500 VA.
Electric range: 8,000 VA.
Water heater: 4,500 VA.
Central heating: 5,000 VA.
Central air conditioning: 4,500 VA (heating load is higher, so we use that).
SMALL HOME

Step 1: General lighting, small-appliance, and laundry loads = 3,600 VA + 3,000 VA + 1,500 VA =
8,100 VA.
Apply demand factors:
First 3,000 VA at 100% = 3,000 VA.
Remaining 5,100 VA at 35% = 1,785 VA.
Total = 4,785 VA.
Step 2: Fixed appliances (range and water heater) = 12,500 VA.
Step 3: HVAC load = 5,000 VA (for heating).
Total load:
4,785 VA+12,500 VA+5,000 VA=22,285 VA
Convert to amperes:
22,285 VA/(1.73*380 V)=33.8 A
The service size required for this home would be 33.87 amps.
COMMERCIAL LOAD
CALCULATIONS
In this module, participants will learn how to perform load calculations for commercial
buildings following NEC Article 220. This includes understanding the specific requirements for
general lighting, receptacle loads, fixed appliances, and specialized commercial equipment. By
the end of the module, participants will be able to calculate total loads for commercial
buildings and ensure compliance with NEC standards for branch circuits, feeders, and service
entrance sizing.
 COMMERCIAL LOAD
CALCULATIONS
The load calculation methods for commercial buildings differ from those used in residential
settings. NEC Article 220 Part IV outlines the rules for calculating loads in commercial
occupancies, including offices, retail spaces, restaurants, and more. These calculations must
account for:
General lighting loads based on the building’s occupancy type.
Receptacle loads for general use.
Special equipment loads, such as for commercial kitchens, HVAC systems, and machinery.
Demand factors that reduce total load based on the assumption that not all loads operate
simultaneously.
STEP-BY-STEP
COMMERCIAL LOAD
CALCULATION
Step 1: General Lighting Load Calculation
NEC 220.12 specifies general lighting loads for various types of occupancies based on the floor
area of the space. The load is calculated in volt-amperes (VA) per square foot. Different types
of buildings have different lighting load requirements:
Office buildings: 3.5 VA per sq. ft.
Retail stores: 3 VA per sq. ft.
Schools: 3 VA per sq. ft.
Hotels/motels: 2 VA per sq. ft.
Warehouses: 0.25 VA per sq. ft.
Example:
For a 2,000 sq. ft. retail store, the general lighting load would be:
2,000 sq. ft.×3 VA/sq. ft.=6,000 VA
The general lighting load is then used to size the branch circuits and feeders.
STEP-BY-STEP COMMERCIAL
LOAD CALCULATION
Step 2: Receptacle Load Calculation
For general-use receptacles in commercial buildings, NEC 220.14 requires a load calculation
based on the number of receptacles or the total floor area. Receptacle loads are assigned 180
VA per outlet.
If the receptacles are spread across the floor area without being individually counted, the NEC
allows for a load estimate based on the square footage of the space. A minimum load of 1 VA
per sq. ft. can be used for receptacles.
Example 1:
If a retail store has 20 general-purpose receptacles:
20 receptacles×180 VA/receptacle=3,600 VA
Example 2:
If the number of receptacles is not known, for a 2,000 sq. ft. retail store, you could estimate:
2,000 sq. ft.×1 VA/sq. ft.=2,000 VA
The higher of the two calculations is typically used to ensure sufficient power is available.
STEP-BY-STEP
COMMERCIAL LOAD
CALCULATION
Step 3: Fixed Appliance Loads
All fixed (permanently installed) appliances in commercial settings must be included in the
load calculation. These loads are taken at 100% of their nameplate rating. Appliances can
include:
Water heaters.
Commercial ovens.
Refrigeration units.
Dishwashers.
Example:
A retail store has a 3,000-watt water heater and a 1,500-watt refrigeration unit. The load
calculation would be:
3,000 W+1,500 W=4,500 VA
STEP-BY-STEP
COMMERCIAL LOAD
CALCULATION
Step 4: HVAC and Special Equipment Loads
For heating, ventilation, and air conditioning (HVAC) systems, the NEC requires you to include
the larger of:
1. The load of the heating equipment.
2. The load of the air conditioning equipment.
In many commercial settings, HVAC systems represent a significant portion of the total load.
Example:
If the air conditioning unit has a load of 5,000 watts and the heating system has a load of 4,000
watts, you would use the 5,000 VA from the air conditioning system.
For commercial kitchens, special equipment such as electric ranges, ovens, fryers, and
dishwashers must be calculated at 100% of their nameplate rating.
STEP-BY-STEP
COMMERCIAL LOAD
CALCULATION
Step 5: Application of Demand Factors
The NEC provides demand factors for lighting, receptacle loads, and certain appliances in
commercial settings. Applying these factors helps reduce the total calculated load by
recognizing that not all loads are used simultaneously.
For lighting:
100% of the lighting load.
Retail store and all others
For receptacles:
100% of first 10 kVA plus 50% of remainder
For kitchen equipment in restaurants or cafeterias, NEC 220.56 allows for a demand factor to
be applied if there are multiple pieces of cooking equipment. The demand factor decreases as
the number of appliances increases.
TOTAL LOAD CALCULATION EXAMPLE
FOR A COMMERCIAL OFFICESION
STATEMENT
Let’s calculate the total load for a 3,000 sq. ft. office building with the following details:
General lighting: 3.5 VA per sq. ft.
30 general-use receptacles.
A water heater rated at 4,000 watts.
HVAC system: 8,000 watts (air conditioning) and 6,000 watts (heating).
Step 1: General Lighting Load
3,000 sq. ft.×3.5 VA/sq. ft.=10,500 VA
Step 2: Receptacle Load
For 30 general-use receptacles:
30 receptacles×180 VA/receptacle=5,400 VA
Step 3: Fixed Appliance Load
The water heater is rated at 4,000 watts:
Step 4: HVAC Load
The air conditioning system has a higher load than the heating system, so we use the AC
load:
8,000 VA
TOTAL LOAD CALCULATION
EXAMPLE FOR A COMMERCIAL
OFFICESION STATEMENT
Step 5: Apply Demand Factors
For lighting, we apply the demand factor from NEC 220.42:
For office buildings, the National Electrical Code (NEC) specifies that the lighting load
demand factor should be calculated at 100% of the total calculated value. This means that
no reduction or demand factor is applied to the lighting load for office buildings, and it must
be included in the service calculation at its full value.
No demand factor is applied to receptacle or fixed appliance loads in this case.
TOTAL LOAD CALCULATION
EXAMPLE FOR A COMMERCIAL
OFFICESION STATEMENT
Total Load Calculation
Total load=10,500 VA (lighting)+5,400 VA (receptacles)+4,000 VA (appliance)+8,000 VA
(HVAC)=27,900 VA
Convert to amperes for a 230/380V three-phase system:
Amps = 27,900 VA /(1.73 * 380) = 42.43 A
In this example, the office building would require a service capable of handling at least 42.43
amps.
KEY TAKEAWAYS
Lighting loads in commercial buildings are calculated based on the occupancy type,
typically using VA per square foot values.
Receptacle loads are calculated using 180 VA per outlet or based on floor area for general-
use receptacles.
Fixed appliances are calculated at 100% of their nameplate rating.
HVAC loads require using the larger of either heating or cooling loads.
Demand factors help reduce total loads for lighting and other specific equipment, ensuring
more efficient electrical system sizing.
INDUSTRIAL LOAD
CALCULATIONS
In this module, participants will learn how to perform electrical load calculations for industrial
settings, in accordance with the NEC. This includes calculating loads for motors, machinery,
and heavy-duty equipment, as well as understanding the specific NEC rules for feeder and
branch circuit sizing in industrial environments. By the end of this module, participants will be
able to calculate accurate industrial loads and ensure compliance with NEC guidelines.
OVERVIEW OF NEC
REQUIREMENTS FOR INDUSTRIAL
LOAD CALCULATIONS
Industrial load calculations are more complex than residential and commercial calculations
due to the presence of heavy machinery, motor loads, and specialized equipment. NEC Article
220 Part V provides guidance for optional load calculations in large industrial installations,
while NEC Article 430 deals specifically with motor loads.
Key factors to consider for industrial load calculations include:
Motor loads (covered in NEC Article 430).
Continuous vs. non-continuous loads.
Demand factors for specific types of industrial equipment.
Feeder and branch circuit sizing based on calculated loads.
MOTOR LOAD CALCULATIONS
(NEC ARTICLE 430)
Motors are the primary load in many industrial installations, and calculating
their loads requires careful attention to NEC rules. NEC Article 430 governs
the calculation of motor loads, covering topics such as conductor sizing,
protection, and overcurrent devices.
Step 1: Full Load Current (FLA) Calculation for Motors
The Full Load Current (FLA) of a motor is the current it draws when operating
at full capacity. NEC Table 430.250 provides the full load current values for
three-phase AC motors, based on their horsepower (HP) and voltage.
Example:
For a 10 HP, 208V, three-phase motor, according to NEC Table 430.250, the full
load current is 30.8 amperes.
MOTOR LOAD CALCULATIONS
(NEC ARTICLE 430)
Motor Load Calculation
Motor load is calculated based on the FLA. The motor load (in VA) is determined by multiplying
the FLA by the system voltage and a factor for three-phase power:
Motor load (VA)=FLA × Voltage× sq. 3
For the 10 HP motor with an FLA of 30.8A at 208V:
Motor load (VA)=30.8 A×208 V×1.732=11,122 VA
MOTOR LOAD CALCULATIONS
(NEC ARTICLE 430)
Step 3: Continuous vs. Non-continuous Loads
NEC defines continuous loads as those that operate for three hours or more. For motors
classified as continuous loads, NEC requires that their load be calculated at 125% of the full
load current.
If the motor is a continuous load:
Motor load=11,122 VA×1.25=13,902 VA
MOTOR LOAD CALCULATIONS
(NEC ARTICLE 430)
for 220/380V three phase system:
Converting to Wattage
1 HP = 746 W
for 10 HP, 380 V motor
P = 10*746 = 7460 W
Converting to VA
S = P/ p.f
assuming p.f = 0.8
S = 746 W/ 0.8 = 933 VA approximately 1000 VA
Therefore, 1 HP = 1000 VA
for 10 HP, 380 V motor
S = 10*1000 = 10,000 VA
Converting to ampere
I = (HP * 1000) / (sq. 3 * 380V) = 1.5 * HP (A)
for 10 HP, 380 V motor
I = 1.5 * 10 = 15 A
MOTOR LOAD CALCULATIONS
(NEC ARTICLE 430)
Step 4: Multiple Motor Load Calculations
If multiple motors are present, NEC requires that all motors be calculated at 100% of their load,
and the largest motor in the installation be increased by an additional 25% for proper
protection.
Example:
If an industrial facility has the following motors:
10 HP motor (380V).
5 HP motor (380V,).
7.5 HP motor (380V).
The load for each motor is calculated individually, and then the largest motor (10 HP) is
adjusted by an additional 25%.
1. 10 HP motor:
2. Full load current = 1.5*10 = 15 A
3. Load = 10*1000 =10,000 VA
4. 5 HP motor:
5. Full load current = 1.5*5 = 7.5 A
6. Load = 5*1000=5,000 VA
7. 7.5 HP motor:
8. Full load current = 1.5*7.5 = 11.25 A
9. Load = 7.5×1000 =7,500 VA
Since the 10 HP motor is the largest, its load is increased by 25%:
10,000 VA×1.25=12,500 VA
The total motor load for the installation is:
12,500 VA+5,000 VA+7,500 VA=25,000 VA
FEEDER AND BRANCH CIRCUIT
LOAD CALCULATIONS
In industrial settings, the feeder is the conductor that supplies power to multiple branch
circuits, and the branch circuits supply individual loads such as motors, lighting, and
machinery.
Step 1: Feeder Sizing
NEC Article 215 covers the calculation of feeder loads. The feeder load is the total connected
load on the feeder, including all branch circuits served by the feeder. In industrial settings,
feeders must be sized to handle 100% of the non-continuous loads and 125% of the continuous
loads.
if the motor loads are continuous, the feeder must handle:
Feeder load=25,000 VA

Step 2: Branch Circuit Sizing

Branch circuits are sized based on the specific load they serve. For motors, the branch circuit
conductors are sized based on 125% of the motor’s FLA (for continuous loads).
For the 10 HP motor, the branch circuit conductor would need to handle:
Branch circuit load=15 A×1.25=18.75 A
This helps ensure the conductor is rated to handle the load safely.
SPECIAL EQUIPMENT
LOAD CALCULATIONS
Industrial settings often include specialized equipment such as welding machines,
compressors, and process machinery. These loads must be calculated according to their
specific NEC requirements.
Welding Equipment (NEC Article 630)
For arc welding machines, the load is calculated based on the rated output of the machine and
the duty cycle. The duty cycle is the percentage of time the machine operates within a 10-
minute period.
For example, if an arc welding machine has a rated output of 200 amps and a duty cycle of
60%, the load calculation would be:
Welding machine load=200 A×0.6=120 A
This load is then used to size the branch circuit conductors and overcurrent protection.
SPECIAL EQUIPMENT LOAD
CALCULATIONS
Air Compressors
Air compressors in industrial environments are treated similarly to motors. Their full load
current is calculated based on the compressor’s rating, and continuous load rules apply if the
compressor runs for more than three hours.
APPLICATION OF DEMAND
FACTORS IN INDUSTRIAL LOAD
CALCULATIONS
The NEC does not specify a demand factor for motors. Instead, it assumes that motors can run
continuously at 100% of their full load rating.

Industrial Loads: The NEC does not provide specific demand factors for industrial facilities like
it does for residential units. For lighting loads, Table 220.12 gives the minimum allowance, but
for industrial facilities, you generally count 100% of the lighting load. For receptacle loads,
Table 220.44 allows a demand factor of 50% for any load over 10 kVA
TOTAL INDUSTRIAL LOAD
CALCULATION EXAMPLE
Let’s calculate the total load for an industrial facility with the following loads:
Two motors:
Motor 1 (15 HP, 380V)
Motor 2 (7.5 HP, 380V)
One air compressor:
5 HP, 380V
General lighting: 10,000 VA.
Welding machine: 200A output, 50% duty cycle.
TOTAL INDUSTRIAL LOAD
CALCULATION EXAMPLE
Step 1: Motor Load Calculation
For the motors, calculate the full load current (note: NEC Table 430.250 for US system)
Motor 1:
FLA = 15*1.5 = 22.5 A
Motor load =15,000 VA.
Motor 2:
FLA = 7.5*1.5 = 11.25 A
Motor load = 7,500 VA.
Since Motor 1 is the largest motor, increase its load by 25%:
15,000 VA×1.25=18,750 VA
Total motor load:
18,750 VA + 7,500 VA = 26,250 VA
TOTAL INDUSTRIAL LOAD
CALCULATION EXAMPLE
Step 2: Air Compressor Load Calculation
For the air compressor:
5 HP, 380V
Load = 5,000 VA

Step 3: Lighting Load Calculation

The lighting load is 10,000 VA.

Step 4: Welding Machine Load Calculation

The welding machine load is:
200 A×0.5=100 A
A×380V×1.732= 100 * 380 * 1.732 = 65,816 VA

Step 5: Total Load Calculation

The total load for the facility is:
26,250 VA (motors) + 5,000 VA (compressor)+10,000 VA (lighting)+65,816 VA (welding)= 107,066
VA
Convert to amperes for a 380V three-phase system:
Total current= 107,066 VA / (380×1.732) =162.6 A
The facility requires a service size of at least 162.6 amps.
KEY TAKEAWAYS
Motor loads are a major consideration in industrial settings, and NEC Article 430 provides
detailed requirements for calculating motor loads.
Feeder and branch circuits must be sized to handle 125% of continuous loads.
Special equipment, such as welding machines and air compressors, must be calculated
according to NEC-specific rules.
Demand factors can help reduce the overall calculated load for feeders and service
entrances, optimizing system sizing while maintaining safety.
SERVICE ENTRANCE SIZING AND
FEEDER CALCULATIONS
Objective:
In this module, participants will learn the principles of service entrance sizing and feeder
calculations in accordance with NEC Articles 215 and 230. The module will cover the procedures
for calculating feeder and service entrance sizes in residential, commercial, and industrial
settings, ensuring compliance with NEC guidelines for safety, load capacity, and overcurrent
protection. By the end of this module, participants will be able to properly size service
entrances and feeders for different types of installations.
SERVICE ENTRANCE SIZING
AND FEEDER CALCULATIONS
The service entrance is the point where electrical power enters a building and is distributed
through the electrical system. Proper sizing of the service entrance conductors, feeders, and
equipment is essential to ensure the safe and reliable operation of the electrical system.
Service Entrance (NEC Article 230): Covers the sizing and installation of service entrance
conductors and overcurrent protection for service equipment.
Feeder Conductors (NEC Article 215): Feeder conductors supply power from the service
equipment to branch circuit panels or distribution points within a building. These
conductors must be sized according to the calculated load and adjusted for continuous
loads, demand factors, and voltage drop.
The NEC provides specific methods and requirements for calculating service sizes based on
the type of occupancy (residential, commercial, industrial), load characteristics, and the
equipment being served.
STEP-BY-STEP SERVICE
ENTRANCE SIZING
The following steps outline how to calculate the proper size of a service entrance for any
building based on the total load calculation. The method applies to both residential and non-
residential installations.

Step 1: Determine the Total Load

Service entrance size depends on the total connected load of the building. This load should
include all lighting, receptacles, appliances, HVAC systems, and any special equipment. Use the
load calculation methods discussed in Lectures 2, 3, and 4 to determine the total load in volt-
amperes (VA).
STEP-BY-STEP SERVICE
ENTRANCE SIZING
Step 2: Apply Demand Factors
The NEC allows for the application of demand factors to reduce the calculated load, especially
in larger installations where not all loads will be used simultaneously.
Residential: Demand factors for general lighting and small appliances are found in NEC
220.42, as discussed in Module 2.
Commercial: Demand factors for lighting loads in commercial buildings are detailed in NEC
220.42, reducing the load when it exceeds 10,000 VA.
Industrial: Demand factors may apply to specialized industrial equipment such as motors,
welding machines, and other heavy machinery.
STEP-BY-STEP SERVICE
ENTRANCE SIZING
Step 3: Calculate the Required Service Amperage
Once the total adjusted load (in VA) has been calculated, convert the load to amperes (A) by
dividing by the system voltage.
For single-phase systems:
Amperage=Total Load (VA) / Phase voltage
For three-phase systems:
Amperage=Total Load (VA) / (sq. 3 * Line Voltage)
STEP-BY-STEP SERVICE
ENTRANCE SIZING
Example: Service Entrance Calculation for a Residential Home
For a 230/380V single-phase residential service:
Total load (calculated in Lecture 2): 19,600 VA.
Divide the total load by 220V:
Amps=19,600 VA/220 V = 89 A
The service size for this home would need to be at least 89 amps to accommodate the total
load safely.
STEP-BY-STEP SERVICE
ENTRANCE SIZING
Step 4: Select Service Conductors and Overcurrent Protection
Once the service amperage is determined, the service entrance conductors and the main
breaker must be selected. The NEC specifies minimum conductor sizes based on the ampacity
of the service.
NEC Table 310.16 provides the allowable ampacities for conductors based on the insulation type
and temperature rating. For example:
For a 115-amp service, using copper conductors with THHN insulation, a minimum conductor
size of #3 AWG would be required.
The main breaker or overcurrent device must be sized based on the calculated load. In the
residential example, the service breaker would be rated at 100 amps.
 FEEDER CALCULATIONS

Determine the Feeder Load

The load on the feeder is the sum of all the loads served by the feeder, including lighting,
receptacles, appliances, and special equipment.
For example, if a subpanel serves:
Lighting: 6,000 VA.
Appliances: 10,000 VA.
HVAC system: 5,000 VA.
The total feeder load would be:
6,000 VA+10,000 VA+5,000 VA=21,000 VA

Step 2: Apply Demand Factors

In certain situations, demand factors can be applied to reduce the total feeder load, especially
in multi-family dwellings or commercial buildings. For example, in a commercial building with a
large lighting load, NEC 220.42 allows the use of demand factors as mentioned previously:
100% of the first 10,000 VA.
50% of the remaining load.
 FEEDER CALCULATIONS
Step 3: Calculate Feeder Ampacity
After adjusting the total feeder load, calculate the feeder conductor size based on the system
voltage. Use the same formulas as for the service entrance calculation.
For a 380V three-phase system, if the total adjusted feeder load is 21,000 VA:
Amperage= 21,000 VA / (sq. 3 * 380V) = 31.9 A
Step 4: Select Feeder Conductors
Using NEC Table 310.16, select the appropriate feeder conductor size based on the ampacity
calculated. For example, if the feeder needs to carry 55 amps, a #6 AWG copper conductor
with THHN insulation would be sufficient.

Step 4: Select Feeder Conductors

Using NEC Table 310.16, select the appropriate feeder conductor size based on the ampacity
calculated. For example, if the feeder needs to carry 55 amps, a #6 AWG copper conductor
with THHN insulation would be sufficient.

Step 5: Select Circuit Breaker

40 A CB would be appropriate
 FEEDER CALCULATIONS
Step 6: Voltage Drop Considerations
For feeders, the NEC recommends limiting voltage drop to 3% for feeder conductors and 5% for
the entire system (including branch circuits). Voltage drop becomes critical in long feeder
runs. The voltage drop formula is:
Voltage Drop= (2×L×I×R) /1000​
Where:
L is the length of the run (in feet or meter).
I is the current (in amperes).
R is the resistance of the conductor (ohms per 1,000 feet or 1000 meter).
If the voltage drop exceeds acceptable levels, it may be necessary to increase the conductor
size.
SUMMARY OF FEEDER SIZING AND
PROTECTION
1. Conductor Sizing (NEC 215.2): Size the feeder conductors based on 100% of non-continuous
loads and 125% of continuous loads.
2. Overcurrent Protection (NEC 240): Select a circuit breaker or fuse that does not exceed the
ampacity of the feeder conductors, rounded up to the next standard size.
3. Adjustment Factors: Apply adjustment factors for ambient temperature or the number of
conductors in the raceway, if applicable.
4. Grounding and Bonding: Follow NEC Article 250 for proper grounding and bonding of feeder
circuits.
5. Voltage Drop: Consider limiting voltage drop to 3% for feeder conductors to ensure efficient
operation.
This process ensures the feeder system is designed to handle the load safely and efficiently
while meeting NEC requirements.
FEEDER SIZING AND PROTECTION
(NEC ARTICLES 215 & 240)
Feeder circuits supply power from a main service panel to subpanels, branch circuits, or other
distribution points in a building. Properly sizing and protecting feeders is critical to ensure the
safe operation of electrical systems and compliance with the National Electrical Code (NEC).
Feeders must be sized to handle the total load of all the equipment they serve and must be
protected from overloads and short circuits.
Key Aspects of Feeder Sizing and Protection:
1. Feeder Conductor Sizing (NEC 215.2(A)(1)):
Conductors must be sized to handle 100% of the non-continuous loads plus 125% of the
continuous loads.
Continuous loads are defined as those operating for three hours or more (e.g., HVAC
systems).

2. Overcurrent Protection (NEC 240):

Overcurrent protection devices (such as fuses or circuit breakers) must be sized to
protect feeder conductors against short circuits, overloads, and ground faults.
Overcurrent protection should not exceed the ampacity of the feeder conductors,
unless adjustments or corrections are made (e.g., for ambient temperature or number of
conductors in a raceway).
FEEDER CONDUCTOR
SIZING (NEC 215.2(A)(1))
The basic formula for feeder conductor sizing is:
Feeder Size=Non-Continuous Load+(Continuous Load×1.25)

Example: Feeder Sizing Calculation

Scenario: A feeder supplies a subpanel with the following loads:
Lighting (continuous load): 12,000 VA.
Receptacles (non-continuous load): 6,000 VA.
Air conditioning unit (continuous load): 8,000 VA.
1. Identify continuous and non-continuous loads:
Continuous load: 12,000 VA (lighting) + 8,000 VA (air conditioning) = 20,000 VA.
Non-continuous load: 6,000 VA (receptacles).
2. Apply the 125% factor to the continuous load:
3. Continuous load adjustment=20,000 VA×1.25=25,000 VA
4. Total feeder load:
Total feeder load=25,000 VA (adjusted continuous)+6,000 VA (non-continuous)=31,000 VA
Convert to amperes: For a 220V single-phase system:
Amps=31,000 VA/ 220 V= 140.9 A
Therefore, the feeder conductors must be sized for at least 140.9 amps.
5. Conductor Selection:
Using NEC Table 310.16, you would select a conductor that can carry at least 140.9A. For
example, for copper conductors with THHN insulation:
A #1 AWG copper conductor is rated for 150A at 75°C, which would be appropriate for this
feeder.
FEEDER OVERCURRENT
PROTECTION (NEC 240)
The overcurrent protection device (circuit breaker or fuse) must be sized to protect the feeder
conductors. The feeder’s overcurrent protection device should not exceed the ampacity of the
conductors, as adjusted for continuous loads and other factors.
NEC 240.4 provides general rules for sizing overcurrent protection based on the
conductor's ampacity.
NEC 240.6 provides standard ratings for overcurrent protection devices (such as 100A, 125A,
150A, etc.).
Step 1: Select Overcurrent Protection Device
The feeder conductors must be protected by an overcurrent protection device (e.g., circuit
breaker) rated for 140.9 A or higher (based on the example above).
Since 140.90A is not a standard circuit breaker size, you would round up to the next standard
size, which is 150A (per NEC 240.6).
Therefore, the feeder would be protected by a 150A circuit breaker.
FEEDER ADJUSTMENT
FACTORS (NEC 310.15(B))
When sizing feeders, you may need to apply adjustment factors or correction factors for
conditions such as high ambient temperature or the number of conductors in a conduit
(raceway).
Ambient temperature correction: If the ambient temperature exceeds the rated
temperature for the conductors, the ampacity of the conductors must be derated. NEC
Table 310.15(B)(2)(a) provides the necessary derating factors.
Number of conductors in a raceway: If more than three current-carrying conductors are
installed in a raceway, the ampacity of the conductors must be reduced according to NEC
Table 310.15(B)(3)(a).
FEEDER ADJUSTMENT
FACTORS (NEC 310.15(B))
Example: Applying Adjustment Factors
If the feeder conductors are installed in a location with an ambient temperature of 40°C and six
current-carrying conductors are in the raceway, the ampacity of the conductors must be
derated as follows:
1. Temperature correction factor (from NEC Table 310.15(B)(2)(a) for 40°C):
For THHN insulation, the correction factor at 40°C is 0.91.
2. Conductor count correction factor (from NEC Table 310.15(B)(3)(a) for six conductors):
The correction factor for 4-6 conductors is 0.80.
3. Derated conductor ampacity: For a #1 AWG copper conductor (normally rated for 150A), the
derated ampacity would be:
4. Derated Ampacity=150 A×0.91×0.80=109.2 A
5. Therefore, if the adjusted ampacity of the conductors is insufficient for the load (e.g., if
14039 A is needed), a larger conductor size would be required.
LOAD CALCULATIONS FOR
SPECIAL APPLICATIONS
Objective:
In this module, participants will explore load calculations for special applications, including
solar photovoltaic (PV) systems, electric vehicle (EV) charging stations, and other emerging
technologies. The module will cover NEC requirements for these systems, how they impact
load calculations, and the proper sizing of conductors and service equipment. By the end of
this module, participants will understand how to incorporate these technologies into load
calculations in a code-compliant manner.
SOLAR PHOTOVOLTAIC (PV)
SYSTEMS (NEC ARTICLE 690)
Solar photovoltaic (PV) systems are increasingly common in residential, commercial, and
industrial settings. NEC Article 690 governs the installation of PV systems, ensuring they are
properly integrated into the building's electrical system and that load calculations account for
their impact.

Step 1: Calculate PV System Output

The output of a PV system is typically rated in kilowatts (kW) or watts (W). This rating reflects
the system’s capacity to generate electrical power under ideal conditions. To integrate the PV
system into load calculations, you need to know the peak power output in watts and the
system voltage.
Example:
A PV system is rated at 5 kW (5,000 watts) and operates at a 220V system voltage.
SOLAR PHOTOVOLTAIC (PV)
SYSTEMS (NEC ARTICLE 690)
Step 2: Sizing Conductors for PV Systems
PV systems generate DC power before it is converted to AC using an inverter. The NEC requires
that conductors in PV systems be sized for the maximum current generated by the system, The
PV array sizing is based on several factors, such as the load, environmental factors (solar
insolation), and system efficiency. Some important considerations include:
Inverter Sizing (NEC 690.8): The inverter must be sized to handle the maximum power
output of the PV array. The output of the array must not exceed the inverter's continuous
power rating. According to NEC 690.8(A)(1), you must calculate the maximum current for a
PV source circuit using: Imax=Isc×1.25
Where:
IscI is the short-circuit current of the PV module, and
1.25 is the safety factor to account for possible overcurrent.
Module Sizing (NEC 690.7): Ensure that the PV module's open-circuit voltage (Voc) and
short-circuit current (Isc) are within the limits allowed by the NEC for the intended
application. Temperature effects on the array must also be considered, as outlined in NEC
690.7.
SOLAR PHOTOVOLTAIC (PV)
SYSTEMS (NEC ARTICLE 690)
Ampacity of Conductors (NEC 690.8(B)): The size of conductors in a PV system is critical.
They need to be capable of carrying 125% of the rated maximum current from the PV
system to account for continuous loads and overcurrent protection. Therefore, conductors
should be sized for at least:
Imin=Imax×1.25
where Imax is the maximum current calculated in the earlier step.
Voltage Drop Consideration (NEC 690.31): Minimize voltage drop by choosing the
appropriate conductor size and minimizing the distance from the array to the inverter and
loads.
SOLAR PHOTOVOLTAIC (PV)
SYSTEMS (NEC ARTICLE 690)
Step 3: Overcurrent Protection:
Overcurrent Protection Devices (NEC 690.9): The NEC requires that each circuit in a PV
system be protected against overcurrent. Typically, fuses or circuit breakers are used.
Devices should be rated to handle the continuous currents in the system with a margin of at
least 125% to account for continuous operation, as specified in NEC 690.9(A).
PV Source Circuit Protection: Overcurrent protection is required on PV source circuits
unless all components are rated to handle the maximum available short-circuit current.
SOLAR PHOTOVOLTAIC (PV)
SYSTEMS (NEC ARTICLE 690)
Disconnecting Means:
PV System Disconnects (NEC 690.13): Each PV system must have a means to disconnect all
current-carrying conductors from the PV system. This allows safe maintenance and service
of the system.
Rapid Shutdown (NEC 690.12): For rooftop PV systems, a rapid shutdown mechanism is
required to quickly de-energize the system in the event of an emergency. This ensures
safety for first responders.
INTERCONNECTION WITH
UTILITY (ARTICLE 705):
Utility Interconnection (NEC 705): When a PV system is interconnected with a utility grid, it
must meet the requirements outlined in Article 705. This includes backfeed prevention,
synchronization, and ensuring the utility side does not become overvoltage or overcurrent.
EXAMPLE
For a small PV system with the following specifications:
PV Module Short Circuit Current (Isc) = 9.0A
PV Module Open Circuit Voltage (Voc) = 40V
Number of PV modules in series = 12
System operating temperature adjustment factor (based on NEC 690.7)
1. PV Array Current Calculation:
2. Iarray max=Isc×1.25=9.0×1.25=11.25A
3. Imin = Imax * 1.25 = 11.25 * 1.25 = 14 A
4. The conductor must be sized to handle this current.
5. Voltage Calculation for Array:
6. Varray = Voc × number of modules in series = 40 × 12 = 480V
7. This total voltage will determine the voltage rating required for the inverter and the
conductors.
By following these NEC guidelines, you ensure that the PV system is properly sized, safe, and
compliant with code requirements. Always consult the latest version of the NEC and local
amendments for any additional requirements or changes.
BACKUP GENERATORS AND
STANDBY POWER SYSTEMS (NEC
ARTICLE 702)
Backup generators and standby power systems provide emergency power during outages.
NEC Article 702 covers the installation of optional standby systems, including load calculations
and integration with the building’s electrical system.
Step 1: Sizing the Generator
The size of a backup generator depends on the total load it needs to supply during an outage.
Typically, only critical loads such as lighting, refrigeration, HVAC, and essential appliances are
included in the generator’s load calculation.
Example:
If a building’s critical loads during an outage include:
Lighting: 4,000 VA.
Refrigerator: 1,500 VA.
HVAC system: 6,000 VA.
The total generator load would be:
4,000 VA+1,500 VA+6,000 VA=11,500 VA
For a 220V single-phase system, the required generator size would be:
11,500 VA / 220 V= 52.27 A
In this case, a 12 kW generator (capable of 53A at 220V) would be sufficient to power the
building’s critical loads.
BILL OF QUANTITY (BOQ) AND
MATERIAL COST ESTIMATION
This module will cover the process of creating a Bill of Quantity (BoQ) and estimating the
material costs for electrical installations. Participants will learn how to break down materials
needed for a project, calculate the quantities, and estimate costs for accurate budgeting and
project management. This new module will ensure that electricians, contractors, and engineers
can plan and execute projects efficiently while managing both materials and costs.

Objective:
By the end of this module, participants will be able to:
Prepare a Bill of Quantity (BoQ) for residential, commercial, and industrial electrical
installations.
Estimate the material costs based on current prices and project needs.
Integrate load calculations and feeder sizing with cost estimates to plan project budgets.
BILL OF QUANTITY (BOQ) AND
MATERIAL COST ESTIMATION
A Bill of Quantity (BoQ) is an itemized list of materials, equipment, and labor required for a
project. It ensures that all required materials are accounted for, preventing material shortages
or over-ordering, while also serving as the basis for cost estimation.
Components of a BoQ for Electrical Installations:
Conduit and Wiring: Sizing and quantity of conductors, conduit, and raceways based on
load calculations and feeder sizing.
Circuit Breakers and Protection Devices: Type and size of circuit breakers and fuses needed
for protection.
Distribution Panels: Main service panels, subpanels, and associated busbars.
Lighting Fixtures and Receptacles: Number and type of lighting fixtures, switches, and
receptacles.
Grounding Materials: Ground rods, clamps, and bonding equipment.
Special Equipment: PV systems, EV chargers, HVAC connections, and other large equipment.
Labor Costs: Estimated labor costs for installation, typically based on the time required and
skill level.
STEPS TO CREATE A BILL
OF QUANTITY
Step 1: Breakdown of the Electrical System
Based on the electrical load and feeder sizing calculations from earlier modules, participants
will break down each component of the electrical system. For example, based on total load:
Conductor sizes and lengths are determined for branch circuits and feeders.
Number of circuit breakers is calculated based on the number of circuits and required
protection.
Panelboard size and number of slots are chosen based on the service load and feeder sizing.

Step 2: Itemized Listing

Each component is listed with its required specifications, such as:
Conductor size and length (e.g., 500 feet of #8 AWG copper THHN wire).
Number of circuit breakers (e.g., 20 15-amp circuit breakers).
Conduit type and size (e.g., 100 feet of 1-inch EMT conduit).
Panels and subpanels (e.g., 100-amp subpanel with 12 slots).
Lighting fixtures and outlets (e.g., 30 LED recessed lighting fixtures and 20 duplex
receptacles).
STEPS TO CREATE A
BILL OF QUANTITY
Step 3: Quantify Materials
After listing all materials, quantities are calculated based on project specifications. For
example, for a residential project with 10 branch circuits, participants will calculate:
Total conductor length: Based on the distance between the panel and outlets/fixtures.
Number of circuit breakers: Based on the circuits and protection requirements.
Conduit lengths: Based on wiring runs, ceiling heights, and wall installations.

Step 4: Material Cost Calculation

Participants will learn how to estimate the cost of materials based on current market prices or
vendor quotes. For each item, they will calculate:
Unit price (e.g., cost per foot of wire, cost per circuit breaker).
Total cost for each line item (e.g., 500 feet of wire at $0.50/ft = $250).
EXAMPLE: BOQ FOR A
RESIDENTIAL ELECTRICAL
INSTALLATION
For a 1,500 square foot single-family home, the following materials and quantities might
be required based on the load calculation and feeder sizing from earlier modules.

item description quantity unit cost ($) total cost ($)

Conductor #12 AWG Copper THHN 1,000 feet 0.50/ft 500.00

Circuit breaker 20A Circuit Breakers 10 10.00 each 100.00

Main Panel 100A Load Center (20 slots) 1 200.00 each 200.00

Sub-Panel 60A Subpanel (12 slots) 1 150.00 each 150.00

Receptacles 15A Duplex Receptacles 20 2.00 each 40.00

EXAMPLE: BOQ FOR A RESIDENTIAL
ELECTRICAL INSTALLATION

item description quantity unit cost ($) total cost ($)

Light Fixtures LED Recessed Lighting 25 15.00 each 375.00

Conduit EMT 1-inch EMT Conduit 200 feet 1.50/ft 300.00

Grounding System 8-ft Ground Rod 1 30.00 each 30.00

Labor Cost Electrician labor (per hour) 40 hours 50.00/hr 2,000.00

EXAMPLE: BOQ FOR A RESIDENTIAL
ELECTRICAL INSTALLATION
Total Material Cost: $3,695.00
Labor Cost: $2,000.00
Total Project Estimate: $5,695.00
STEPS TO CREATE A
BILL OF QUANTITY
8. Estimating Labor Costs
Labor costs can vary depending on the complexity of the installation, the location of the
project, and the expertise required. Participants will learn how to estimate labor costs based
on:
Time required: Estimating the number of hours needed for installation based on experience
or industry standards.
Hourly labor rates: Accounting for rates that may vary between regions, types of work, or
skill levels (e.g., apprentice, journeyman, or master electrician).
Specialized labor: For tasks like integrating PV systems, EV chargers, or complex industrial
installations.
9. Material Cost Fluctuations
account for potential cost fluctuations in materials, which can impact the overall budget. Key
considerations include:
Copper prices: Conductors, which are largely made of copper, can fluctuate in price.
Bulk purchasing: Discounts available when buying large quantities.
Supplier pricing: How to get accurate and up-to-date quotes from suppliers to ensure
budget accuracy.
PROJECT MANAGEMENT
Objective:
In this final module, participants will learn how to apply the skills they've gained in load
calculation, feeder sizing, and material cost estimation to real-world projects. The module will
focus on effective project management, ensuring that the design, budgeting, scheduling, and
execution of electrical installations meet both technical and financial goals.
PROJECT MANAGEMENT
Managing Electrical Projects
Proper project management is essential to completing electrical installations on time, within
budget, and in compliance with NEC standards. In this section, participants will learn key
project management principles for electrical projects, including planning, resource allocation,
scheduling, and monitoring.
Key Steps in Project Management:
1. Project Planning:
Define the project scope, including total square footage, required electrical loads, and
any special equipment (e.g., PV systems, EV chargers, industrial motors).
Create a work breakdown structure (WBS), identifying key tasks like load calculations,
panel sizing, conduit installation, wiring, and testing.
2. Resource Allocation:
Allocate materials (e.g., conductors, conduits, protection devices) and ensure sufficient
quantities are ordered based on the Bill of Quantity (BoQ).
Assign personnel to specific tasks, such as journeyman electricians for conduit runs and
apprentices for pulling wire.
3. Scheduling:
Use a Gantt chart or project timeline to schedule key tasks like trenching, conduit
installation, wiring, panel installation, testing, and commissioning.
Coordinate inspection schedules with local authorities to ensure each phase of work is
certified before proceeding to the next.
PROJECT MANAGEMENT
4. Monitoring and Adjustments:
Continuously monitor material use, labor hours, and work progress to ensure the project
remains on track.
Adjust timelines and budgets as needed to accommodate delays, material shortages, or
changes in scope.
INTEGRATING NEC
COMPLIANCE INTO PROJECT
EXECUTION
Participants will learn how to ensure that their project remains fully NEC-compliant during
execution, from design through to the final inspection. This includes the following critical
areas:
Pre-Construction Phase:
Before beginning any electrical work, verify that load calculations, feeder sizing, and circuit
protection meet NEC standards (e.g., NEC 220 for load calculations, NEC 215 for feeder
sizing, NEC 240 for overcurrent protection).
During Construction:
Ensure that conductors are installed according to NEC rules for ampacity and voltage
drop (NEC 310.16).
Verify that branch circuits, feeders, and protection devices (e.g., circuit breakers, fuses)
are sized and installed correctly to protect against overcurrent conditions (NEC 240).
Follow grounding and bonding practices in line with NEC Article 250 to prevent electrical
shock hazards.
Final Inspection and Testing:
Ensure that all final testing is performed, including checking circuit continuity, verifying
breaker trip settings, and testing grounding systems.
Prepare for the final inspection by reviewing NEC compliance, ensuring all
documentation (e.g., BoQ, material lists, as-built plans) is ready for the inspector.
RISK MANAGEMENT IN
ELECTRICAL PROJECTS
This section will focus on identifying risks that can arise during electrical installations and
learning how to mitigate them effectively. These risks include:
Common Risks:
Material Shortages: Fluctuations in material availability or price (e.g., copper conductors,
conduit).
Labor Delays: Delays due to weather, personnel shortages, or unexpected complications in
the installation process.
Code Violations: Non-compliance with NEC standards, leading to failed inspections, rework,
and project delays.
Risk Mitigation Strategies:
Pre-ordering Materials: Anticipate material needs based on the BoQ and project timeline,
and place orders early to avoid shortages or price increases.
Regular Progress Reviews: Hold weekly project review meetings to identify any delays or
risks, and adjust labor schedules or material orders accordingly.
Pre-Inspection Checks: Perform thorough internal reviews to ensure NEC compliance
before formal inspections, reducing the risk of costly rework.
COST CONTROL AND BUDGETING
THROUGHOUT THE PROJECT
One of the most significant challenges in electrical installations is maintaining control over the
budget. This section will provide participants with strategies to monitor and control costs
throughout the project.
Cost Management Techniques:
Tracking Material Usage: Continuously compare actual material usage against the original
BoQ to identify potential overuse or shortages early.
Labor Tracking: Monitor labor hours daily to ensure that tasks are being completed
efficiently and that labor costs are within the budgeted amount.
Change Orders: Manage changes in project scope carefully by issuing change orders when
additional work is required, ensuring that any adjustments to the project timeline or budget
are accounted for.
Budget Adjustments:
Adjust the project budget as needed to accommodate material price changes, delays, or
additional labor requirements, while ensuring that profit margins remain intact.
COMPLETE EXAMPLE
This example will guide you through the process of:
1. Estimating various electrical loads in a typical residential building.
2. Designing branch circuits for these loads, including selecting the appropriate circuit
breakers and conductor sizes.
3. Designing the main feeder and selecting the main breaker.
4. Applying adjustment factors and correction factors where necessary, ensuring compliance
with the National Electrical Code (NEC).
COMPLETE EXAMPLE
Step 1: Load Estimation (NEC 220)
Example Scenario:
A single-family home with a 220/380V single-phase system. The home has the following loads:
General lighting and receptacle loads: 2,000 square feet.
Kitchen appliances: Electric range, refrigerator, and microwave.
Laundry: Electric dryer.
HVAC system: Central air conditioning and electric heating.
Other loads: Garage door opener and water heater.
1.1 General Lighting and Receptacle Loads (NEC 220.12)
The general lighting and receptacle load is calculated based on 3 VA per square foot (NEC
Table 220.12 for dwelling units).
General lighting load=2,000 sq. ft.×3 VA/sq. ft.=6,000 VA
1.2 Small Appliance Circuits (NEC 220.52(A))
Two small-appliance branch circuits are required for kitchen receptacles (NEC 210.11(C)(1)).
Small appliance load=2×1,500 VA=3,000 VA
1.3 Laundry Circuit (NEC 220.52(B))
One laundry circuit is required.
Laundry load=1,500 VA
COMPLETE EXAMPLE
1.4 Kitchen Appliances (NEC 220.55)
Electric range: The range is rated at 10,000 VA. Using NEC Table 220.55 for an electric range
with one unit, the load is 8,000 VA after applying demand factors.
Refrigerator: The refrigerator is considered a continuous load, with a rating of 1,200 VA.
Microwave: Rated at 1,200 VA.
1.5 Laundry Appliance
Electric dryer: Rated at 5,000 VA. Using NEC Table 220.54, the dryer load remains 5,000 VA.
1.6 HVAC Load (NEC 220.82(C))
Air conditioning unit: Rated at 5,500 VA.
Electric heater: Rated at 4,500 VA.
Since the air conditioner and heater won’t operate simultaneously, we will use only the larger
load of the two:
HVAC load=5,500 VA
1.7 Water Heater
Water heater: Rated at 4,500 VA.
1.8 Other Loads
Garage door opener: Rated at 600 VA.
COMPLETE EXAMPLE
Step 2: Calculate Total Load
2.1 Apply Demand Factors for Lighting and Appliance Circuits (NEC 220.42 and 220.52)
General lighting and small appliances: NEC allows for the application of demand factors.
The first 3,000 VA is taken at 100%, and the remainder at 35%.
Adjusted load=3,000 VA+ 6,000 VA= 9,000 VA =(3,000 VA) + (6,000 VA * 0.35) = 3,000 VA + 2,100
VA = 5,100 VA
2.2 Total Load Calculation
Sum up all the loads:
Total load=5,100 VA (adjusted lighting and small appliance)+1,500 VA (laundry)+8,000 VA
(range)+1,200 VA (fridge)+1,200 VA (microwave)+5,000 VA (dryer)+5,500 VA (HVAC)+600 VA
(garage door opener)=28,100 VA

Step 3: Convert to Amperes (A)

For a 220/380V single-phase system:
Amps=28,100 VA / 220 V=127.72 A
COMPLETE EXAMPLE
Step 4: Branch Circuit Design
Now, let's design the branch circuits for individual loads and select the proper conductor size
and breaker.
4.1 Lighting and General Receptacle Circuits
These circuits will be split into multiple 15A and 20A circuits.
Load per lighting circuit: Assume 1,500 VA for each lighting/receptacle circuit.
Current per circuit:
Amps=1,500 VA / 220 V=6.81 A
Breaker size: 15A circuit breaker.
Conductor size: Based on NEC Table 310.16, use #14 AWG copper with THHN insulation (rated
for 15A).

4.2 Kitchen Appliances

Refrigerator and microwave: Each appliance uses a separate circuit.
Load: 1,200 VA for each appliance.
Current:
Amps=1,200 VA / 220 V=5.45 A
Breaker size: 15A circuit breaker.
Conductor size: #14 AWG copper for each circuit
COMPLETE EXAMPLE
4.3 Electric Range
Load: 8,000 VA.
Current:
Amps=8,000 VA / 220 V=36.36 A
Breaker size: 40A breaker (next standard size).
Conductor size: Based on NEC Table 310.16, use #8 AWG copper (rated for 40A).
4.4 Electric Dryer
Load: 5,000 VA.
Current:
Amps=5,000 VA / 220 V=22.72 A
Breaker size: 30A breaker.
Conductor size: #10 AWG copper.

4.5 HVAC System

Load: 5,500 VA.
Current:
Amps=5,500 VA / 220 V=25 A
Breaker size: 30A breaker.
Conductor size: #10 AWG copper.
COMPLETE EXAMPLE
Step 5: Main Feeder Design
5.1 Main Feeder Conductor Sizing
Total current: 127.72 A.
Continuous loads (such as lighting): Must be increased by 125% (NEC 215.2).
Continuous load: Lighting and general receptacles = 5,100 VA.
Adjusted continuous load:
5,100 VA×1.25=6,375 VA
Total adjusted load: Replace 5,100 VA with 6,375 VA.
Total adjusted load=28,100−5,100+6,375 = 29,375 VA
Adjusted current:
Amps=29,375 VA / 220 V=133.52 A

5.2 Conductor Size for Feeder

Based on NEC Table 310.16, for 133.52 A, use #1/0 AWG copper conductors with THHN
insulation (rated for 133.52 A, but since it's a service feeder, NEC 240.4(B) allows rounding up
to the next breaker size).
5.3 Main Breaker Size
Main breaker size: Since the calculated load is 133.52 A, round up to the next standard
breaker size, which is 150 A (NEC 240.6).
5.4 Corrected feeder size # 2/0
COMPLETE EXAMPLE
Step 6: Voltage Drop Consideration (NEC 215.2(A)(4))
To minimize voltage drop, the NEC recommends:
3% voltage drop for feeders.
5% total voltage drop for the entire system (including branch circuits).
For long feeder runs, consider increasing the conductor size. For example, if the feeder run is
long (e.g., 100 feet or more), you may need to use larger conductors (e.g., #2/0 AWG) to reduce
voltage drop and maintain efficient operation.
COMPLETE EXAMPLE
Cost Estimation for the Residential Electrical System Example
To provide a cost estimate for the electrical system design example, we will break down the
costs into materials (conductors, circuit breakers, panels, etc.) and labor. This cost estimate
assumes standard market prices for materials and industry-standard labor rates. Costs may
vary depending on location, project scale, and specific supplier pricing.

1. Material Costs Breakdown

The primary materials needed for the installation are:
Conductors (wiring).
Circuit breakers.
Panels (main service panel, subpanels, etc.).
Conduit and other protective materials.
Other fixtures such as receptacles, outlets, switches, etc.
COMPLETE EXAMPLE
1.1 Conductor ( Wiring)

cost per Total cost

description size length
foot ($) ($)

#1/0 AWG
Main Feeder Wire 75 feet 4.00 300.00
Copper

#14 AWG
Lighting Circuits 500 feet 0.30 150.00
Copper

#12 AWG
Receptacle Circuits 200 feet 0.40 80.00
Copper

#10 AWG
Dryer Circuit 50 feet 0.90 45.00
Copper

#10 AWG
HVAC Circuit 50 feet 0.90 45.00
Copper

#10 AWG 45.00

Water Heater Circuit 50 feet 0.90
Copper
COMPLETE EXAMPLE

cost per Total

description size length
foot ($) cost ($)

Garage Opener #14 AWG

30 feet 0.30 9.00
Circuit Copper

Grounding #6 AWG
30 feet 1.00 30.00
Wire Copper

Miscellaneous Various 0.50

100 feet 50.00
Wiring sizes (average)

Total for
816.50
Conductors
COMPLETE EXAMPLE 1.2 Circuit Breakers

Load Type Breaker Size Quantity Cost per Breaker ($) Total cost ($)

Main Feeder Breaker 150A (main) 1 120.00 120.00

120.00
Lighting/Receptacles 15A/20A 8 (15A), 4 (20A) 10.00

25.00
Electric Range 40A 1 25.00

20.00
Dryer 30A 1 20.00

20.00
HVAC System 30A 1 20.00

Water Heater 30A 1 20.00 20.00

Miscellaneous Circuits Various (15-30A) 2 10.00 20.00

Total for Breakers 345.00

COMPLETE EXAMPLE
1.3 Electrical Panels

Description Quantity Cost per Unit ($) Total cost ($)

Main Service Panel

1 600.00 600.00
(150A)

Subpanel (60A) 1 150.00 150.00

Total for Panels 750.00

COMPLETE EXAMPLE
1.4 Other Materials

Description Quantity Cost ($) Total cost ($)

Conduit (EMT, 1 inch) 100 feet 1.50/foot 150.00

Receptacles, switches, etc. 20 receptacles 2.00 each 40.00

Lighting fixtures (LED) 10 fixtures 50.00 each 500.00

Miscellaneous items 200.00

Estimated
(boxes, fasteners, etc.)

Total for Other Materials 890.00

COMPLETE EXAMPLE
2. Labor Costs
The labor costs are estimated based on industry standard labor rates for electricians. Rates
can vary depending on location and experience level.
Labor Breakdown:

Total Labor Cost ($)

Task Estimated Time (Hours) Labor Rate ($/Hour)

Main Service Panel Installation 8 60.00 480.00

Branch Circuit Wiring 20 50.00 1,000.00

Conduit Installation 10 50.00 500.00

600.00
Receptacle and Fixture Installation 12 50.00

300.00
Final Testing and Inspection 5 60.00

Total Labor Cost 2,880.00

COMPLETE EXAMPLE
3. Total Cost Estimate
Summary of Material and Labor Costs:

Description Total Labor Cost ($)

Conductors (Wiring) 816.50

Circuit Breakers 345.00

Electrical Panels 750.00

Other Materials 890.00

Total Materials 2,801.50

Labor Costs 2,880.00

Grand Total 5,681.50

COMPLETE EXAMPLE
4. Additional Considerations
Permit Fees: Additional costs may be incurred for local electrical permits, which can range
from $100 to $500 depending on the location.
Contingency: It's a good idea to add a 5-10% contingency for unforeseen expenses, such as
material price fluctuations or minor changes to the scope of work.
Contingency (10%): $568.15.
Total with contingency: $6,249.65.

Conclusion
The total cost estimate for this residential electrical system is approximately $6,249.65, which
includes:
$2,801.50 in materials.
$2,880.00 in labor costs.
10% contingency for unforeseen costs.
This estimate ensures that all necessary components (conductors, breakers, panels, and other
materials) are accounted for, while complying with NEC requirements. Labor costs are based
on standard electrician rates, and additional costs such as permits or final adjustments are
factored in through the contingency.
SINGLE LINE DIAGRAM