We often get this question from Plant and facility leaders: “Do we have enough power to add another machine?”
Whether it’s a new production equipment at a manufacturing plant or a piece of medical equipment in a healthcare facility, the challenge is the same: you’re asked to add electrical load, but you don’t know if your distributions system can handle it. Without proper analysis, adding equipment can lead to overloaded circuits, nuisance trips, or even electrical fires, which can create costly downtime and safety incidents..
Fortunately, there are proven tools that take the guesswork out of capacity planning: load studies, one-line diagrams, and infrared thermography. Together, these give facility managers the confidence to expand safely and in compliance with industry standards.
Facility managers are constantly asked to install or relocate machines. But without knowing how much spare capacity the electrical system truly has, each new request poses a risk.
Common problems when skipping proper analysis include:
- Overloading distribution panels or transformers.
- Breakers tripping and disrupting operations.
- Equipment damage from overheated circuits.
- Increased fire and arc flash hazards.
A load study is an electrical investigation that uses a power logger or energy meter to record voltage, current (amperage), and power demand continuously over a period of about 30 days. This monitoring captures normal operating conditions, shift variations, and peak demand cycles.
The National Electrical Code (NEC) Section 220.87 requires measured demand data (typically from a 30-day study) before connecting new loads to an existing system.
Benefits of a Load Study:
- Confirms whether your facility has spare capacity.
- Prevents overloads and unplanned downtime.
- Provides documentation for permits and compliance.
- Avoids unnecessary or oversized electrical upgrades.
Think of it as a stress test for your electrical system. Instead of guessing, you’ll have hard data on whether the infrastructure can support your next machine.
For the entire Facility, we can do a “back-of-the-envelope” Load Study Desktop Calculation. Here are the 5-Steps:
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Get the Utility bill from the peak month of usage. Say August to account for the peak cooling season.
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Find the Apparent demand (kVA): the highest short-interval average of apparent power your site drew in the billing period. Let’s use 800kVA for this example.
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Ensure you know the Amps and Voltage of your incoming service. ie 2,000 amps at 480 volts.
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Plug the data into this formula to get peak amp demand. Peak Amps = (kVA * 1,000) / (Radical 3 * Voltage).
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- (800kVA * 1,000) / (radical 3 * 480) = 962 amps
- 2,000amp service * 80% = 1,600amps (only load 80% of capacity by code). 962 amps / 1,600 amps =60%
A one-line diagram (also called a single-line diagram) is a schematic that shows how electricity flows through your facility—from the utility service, through transformers and switchgear, down to panels and equipment.
An accurate one-line diagram is essential for:
- Identifying which feeder or panel supplies a given machine.
- Ensuring safe lockout/tagout during maintenance.
- Supporting NFPA 70E (Standard for Electrical Safety in the Workplace) arc flash analysis.
- Speeding up troubleshooting during outages or emergencies.
Having an accurate one-line diagram will allow your team to ensure metering devices are located in the correct part of the distribution system to ensure the data supplied in the load studies delivers actionable data on where additional equipment/load can be added to the system.
When circuits or connections are overloaded, they generate heat long before a breaker trips. Infrared thermography (IR) uses thermal imaging cameras to detect these hot spots in real time.
Under NFPA 70B (2023), facilities must perform infrared inspections at least annually as part of a preventive maintenance program.
IR thermography helps facility managers:
- Detect existing overloaded circuits before adding new machines.
- Identify loose connections or imbalances that create hidden risks.
- Validate that systems remain stable after new equipment is installed.
In short, IR scans provide the “visual proof” of how your system is performing under load. In short, IR scans provide the “visual proof” of how your system is performing under load. Another useful data point on load and the capacity of the distribution system.
- NEC 220.87: Requires 30-day load studies to confirm capacity before modifications.
- NFPA 70B (2023): Requires annual infrared inspections and condition-based preventive maintenance.
- NFPA 70E (2024): Requires up-to-date one-line diagrams for arc flash safety programs.
- OSHA 29 CFR 1910: Requires employers to maintain electrical equipment in safe operating condition.
Compliance isn’t just paperwork — it protects your people, your equipment, and your facility.
Many vendors stop at providing data or reports. At C&H Electric, we deliver full-service solutions:
- Load Studies: Using advanced power loggers to analyze demand.
- One-Line Diagrams: Creating or updating your system blueprint.
- Infrared Thermography: Identifying hot spots and hidden overloads.
- Repairs and Upgrades: Correcting deficiencies to ensure compliance and reliability.
We serve key facilities across Connecticut—including healthcare, manufacturing, government, education, and commercial buildings.
Buy a solution, not just a report.
Ready to Plan Your Next Expansion Safely?
Adding a new machine without proper analysis is a gamble. With a load study, one-line diagram, and infrared scan, you’ll know exactly what your system can handle — and what upgrades may be needed.
Let C&H Electric help you protect your facility, your workforce, and your uptime.
References
- National Fire Protection Association (NFPA). (2023). NFPA 70B: Standard for electrical equipment maintenance (2023 ed.). NFPA.
- National Fire Protection Association (NFPA). (2024). NFPA 70E: Standard for electrical safety in the workplace (2024 ed.). NFPA.
- National Electrical Code (NEC). (2023). NFPA 70: National Electrical Code (2023 ed.), Section 220.87. NFPA.
- Occupational Safety and Health Administration (OSHA). (2023). 29 CFR Part 1910 – Subpart S: Electrical standards. U.S. Department of Labor.
- Fluke Corporation. (2022). A guide to 30-day load studies with Fluke power and energy loggers. Fluke Corporation.
- Spark Power. (2023). Why one-line diagrams are a must-have in every manufacturing plant. Spark Power.