About CalcPanel
Built by engineers, for engineers. CalcPanel is developed by a team of experienced industrial electrical engineers with over 40 years of combined field experience in power systems design, factory automation, and industrial facility management.
Our Team
CalcPanel is developed and maintained by a dedicated team of licensed electrical engineers and industrial automation specialists. Our team brings decades of hands-on experience from designing and troubleshooting electrical systems in manufacturing plants, chemical facilities, data centers, and commercial buildings.
Core Team Expertise
- Chief Engineer: 15+ years of industrial electrical system design, specializing in 3-phase power systems, transformer sizing, and factory load calculations. Previously worked on projects for Fortune 500 manufacturing facilities.
- Senior Power Systems Engineer: 12+ years of experience in electrical distribution design, power factor correction, and energy optimization. Former Schneider Electric application engineer with expertise in industrial automation.
- HVAC & Building Systems Specialist: 10+ years in commercial and industrial HVAC system design, load calculations, and energy efficiency optimization. Certified in ASHRAE standards and building energy modeling.
- PLC & Automation Expert: 8+ years of experience in industrial automation, PLC programming, and troubleshooting. Specialized in Siemens, Allen-Bradley, and Schneider Electric systems.
Our Experience
Our team has collectively worked on hundreds of industrial projects, from small workshop electrical upgrades to multi-megawatt facility designs. We've designed electrical systems for:
- Manufacturing Facilities: Automotive plants, food processing facilities, textile mills, and assembly lines
- Chemical & Process Industries: Petrochemical plants, pharmaceutical facilities, and water treatment plants
- Data Centers: UPS sizing, backup power systems, and critical load calculations
- Commercial Buildings: Office complexes, retail centers, and mixed-use developments
This real-world experience directly informs how we build our calculators. Every tool reflects actual field conditions, common challenges engineers face, and industry best practices we've learned through years of hands-on work.
Standards & Compliance
All CalcPanel calculators are developed in strict adherence to recognized international engineering standards:
- IEEE Standards: IEEE 141 (Power Systems), IEEE 519 (Harmonics), IEEE 1547 (Distributed Resources)
- IEC Standards: IEC 60909 (Short-circuit calculations), IEC 60076 (Transformers), IEC 60364 (Electrical Installations)
- NEC (NFPA 70): National Electrical Code compliance for breaker sizing, conductor selection, and safety margins
- ASHRAE Standards: ASHRAE 90.1 (Energy Efficiency), ASHRAE 62.1 (Ventilation), Manual J/N (Load Calculations)
- NEMA Standards: Motor ratings, motor protection, and industrial equipment specifications
Our formulas and calculation methods are cross-referenced with official standard documents and validated against real-world measurements. We regularly update our tools to reflect the latest standard revisions and industry best practices.
Project Highlights
Here are a few examples of how our field experience shapes the tools we build:
Case Study 1: Chemical Plant Motor Load Analysis
Challenge: A 50HP 3-phase motor installation at a chemical processing facility was experiencing frequent breaker trips despite calculations showing adequate capacity.
Our Analysis: On-site measurements revealed actual current draw of 68A during startup, significantly higher than the calculated 52A. The discrepancy was due to high starting torque requirements and voltage drop in the long feeder circuit.
Solution: We recommended a 100A breaker with 25% safety margin and verified the feeder cable sizing. This experience directly informed our Factory Load Calculator's safety margin recommendations and starting current considerations.
Result: Zero breaker trips in 12 months of operation, and the facility was able to optimize their electrical distribution system based on our analysis.
Case Study 2: Data Center UPS Sizing
Challenge: A 500kW data center needed to determine UPS runtime for critical load during power outages, with mixed IT equipment and HVAC loads.
Our Analysis: We calculated actual load diversity (not all equipment runs at 100% simultaneously), accounted for power factor variations between IT equipment (0.95-0.98 PF) and HVAC systems (0.85-0.90 PF), and factored in battery aging.
Solution: Recommended 600kVA UPS with 15-minute runtime at 80% load, accounting for load growth and battery degradation over 5 years. This multi-factor approach is now built into our UPS Runtime Calculator.
Result: The data center achieved their target runtime requirements while optimizing capital costs, avoiding both undersizing and excessive oversizing.
Case Study 3: Factory Load Expansion Planning
Challenge: A manufacturing facility needed to add 200kW of new production equipment but wasn't sure if their existing 500kVA transformer could handle the additional load.
Our Analysis: We analyzed existing load patterns, applied proper diversity factors (not all equipment runs simultaneously), calculated actual demand load vs. connected load, and assessed transformer loading under peak conditions.
Solution: Determined that with proper load scheduling and diversity factors, the existing transformer had 180kW of available capacity, sufficient for the new equipment. Recommended load management strategies to prevent simultaneous peak operation.
Result: The facility avoided a $50,000 transformer upgrade by optimizing load distribution, saving significant capital costs while maintaining system reliability.
What We Do
CalcPanel provides a comprehensive suite of professional-grade engineering calculators covering critical aspects of industrial electrical and mechanical systems:
- Electrical Power Systems: 3-phase power calculations, factory load analysis, transformer sizing, and power factor optimization
- Backup Power Systems: UPS runtime estimation, battery sizing, and critical load calculations
- HVAC Design: Heating and cooling load calculations based on ASHRAE methods
- Energy Management: Energy consumption estimation, cost analysis, and efficiency optimization
- Troubleshooting Tools: PLC error code lookup, diagnostic guides, and common mistake identification
Every calculator is built with the same rigor we apply to professional engineering projects: accurate formulas, realistic assumptions, appropriate safety margins, and clear explanations of results.
Our Commitment
We are committed to providing accurate, reliable, and professionally validated engineering tools. Our calculators undergo rigorous testing against real-world scenarios and standard engineering practices. However, please note:
- Our tools are designed for preliminary design, estimation, and planning purposes
- For final engineering design and critical applications, always consult with qualified, licensed engineering professionals
- Local building codes, utility requirements, and site-specific conditions may require adjustments to our calculations
- We regularly update our tools based on standard revisions and industry feedback
Contact Us
Have questions, suggestions, or feedback? We'd love to hear from you! Whether you're an engineer using our tools on a project, a student learning industrial calculations, or a facility manager optimizing your systems, your input helps us improve.
Please contact us at contact@calcpanel.com or visit our Contact page for more information. We aim to respond to all inquiries within 1-2 business days. We're always interested in hearing about real-world applications of our calculators and how we can make them more useful for your work.