the importance of knowing the basics of generator sizing calculations
TRANSCRIPT
Your Industrial Resource Center
Is the generator needed for commercial
or residential use?
What is the five digit ZIP code for your
location? Zip lookup for major cities
Generators Home Free Price Quotes Buyer's Guide Related Articles
View all categories | Help
Compare FREE Price Quotes from the Leading Generator Brands
Choose...
Continue for Free Quotes
Home > Industrial > Generators > Related Articles > Basic Calculations for Sizing
Generators and the Impacts of Certain Loads
Power Quality and Generators, Part 8: Basic
Calculations for Sizing Generators and the
Impacts of Certain Loads
Knowing the basics of generator sizing calculations will help the system designerunderstand the impact that certain loads and starting methods have on the ultimate size ofthe standby generator.
Consulting-Specifying Engineer - June 16, 2005
Keith Lane, P.E., RCDD/NTS Specialist, LC, LEED APVice President - EngineeringSASCO, Seattle
Editor's Note: This is the eighth article in a series covering
basic engineering and code issues for standby generators and
critical systems used in commercial building. This month's
column covers the basic calculations for sizing standby
generators.
Articles in this series
Once the starting kVA (sKVA), starting kW (sKW) and the alternator kW requirements are
calculated by hand for generator sizing, these values are fed into sizing software to determine a
particular manufacturer's recommended generator sizes. Although many generator simulation
software programs are available, knowing the basics of generator sizing calculations will help the
system designer understand the impact that certain loads and starting methods have on the
ultimate size of the standby generator.
It is common for a system's sKVA—or its sKW and maximum allowable transient voltage drop—to
determine the size of the generator. Motors can draw six times the full-load amps during
startup. The motor's NEMA code letter, which identifies the starting kVA/hp, is a representation
of the starting inrush current. The example below uses a NEMA “F” motor. Based on this letter
code, the motor will draw approximately 5.3 kVA/hp. Using the following calculation for a 150 hp
motor with 91% efficiency and 0.91 power factor, the motor will draw approximately 5.9 times
the full-load current during motor starting:
Calculation #1
150 hp x 5.3 kVA/hp = 795 kVA = 956.6 amps @ 480 volt/3 phase (amps during
startup)
(150 hp x 0.746 kW/hp) / 0.91 (efficiency) = 123.0 kW (running kW)
123.0 kW / 0.91 (power factor) = 135.1 kVA = 162.5 amps (represent full-load amps)
956.6 amps (during startup) / 162.5 A (full-load amps) = 5.9 (times full-load current)
High-efficiency motors can draw ten or more times the full-load current. As a comparison, for a
motor with a NEMA “K” rating (8.5 kVA/hp), the inrush current would have been significantly
higher (9.4 times full-load current). The following calculation uses a 150-hp motor with 91%
efficiency and 0.91 power factor:
Calculation #2
Featured Suppliers
Supplier Brochures
Briggs & StrattonGeneratorsDiesel Service & SupplyGeneratorsJasper GeneratorsStandby Power USAGenerators
Search by Location
We can connect you withgenerators dealers that serveyour specific region.
Start a search...
Mentioned In...
"BuyerZone is the sort of sitethat the Internet seemsdesigned for... an amazingservice."
See Also
CMMS SoftwareCNC MachinesCNC RoutersFork lifts For SaleGeneral SteelOrder PickersPole BarnSteel Building PricesUsed CNC RoutersUsed Forklifts
Supplier Program
Do you sell Generators orother business products orservices?
Sign up for our generatorslead generation program
Search by State
Alabama GeneratorsAlaska GeneratorsArizona GeneratorsArkansas GeneratorsCalifornia GeneratorsColorado GeneratorsConnecticut GeneratorsD.C. Generators
More
Link to this article
Cat Gas GeneratorNatural gas gensets, 9 to 6000kW Highhorsepower, low emissions
Siemens answers:Efficient energy supply with OffshoreWindparks.
Ads by Google
10/24/2010 The importance of knowing the basics…
buyerzone.com/…/rbic-power-quality-… 1/5
150 hp x 8.5 kVA/hp = 1,275 kVA = 1,534 amps @ 480 volt/3 phase (amps during
startup)
(150 hp x 0.746 kW/hp) / 0.91 (Efficiency) = 123.0 kW (running kW)
123.0 kW / 0.91 (power factor) = 135.1 kVA = 162.5 amps (represent full-load amps)
1,534 amps (amps during starting) / 162.5 amps (full-load amps) = 9.4 (times full-load
current)
This illustrates that the starting of motors can dramatically affect the inrush current and
associated sKVA and the sKW required and may exceed the maximum sKVA or the sKW of a
generator set that would otherwise be large enough to serve the steady state load. This could
require an oversized generator set based solely on the motor starting requirements of the
electrical system.
To clarify this issue, I will use an example with the same load profile but with two different
methods of motor starting. These simple examples will include lighting and miscellaneous loads
as well as motor starting with an across the line starter in one example and a solid-state starter
in another example.
Example #1: Motor with an across the line starter
Motor Load: 150-hp motor, NEMA “F” with a 0.28 starting power factor
Running power factor of 0.91 and an efficiency of 0.91.
NEMA Code Letter “F” = 5.3 kVA/hp
sKVA = 150 hp x 5.3 kVA/hp = 795 kVA
sKW = 795 kVA x 0.28 (starting power factor) = 222.6 kW
Running kVA = 123.0 kW / 0.91 (power factor) = 135.1 kVA
Running kW = (150 hp x 0.746 kW/hp) / 0.91 (Efficiency) = 123.0 kW
Lighting Load: 75 kVA at 0.9 power factor
sKVA = 75 kVA
sKW = 75 kVA x 0.9 power factor = 67.5 kW
Running kVA = 75 kVA
Running kW = 75 kVA x 0.9 power factor = 67.5 kW
Miscellaneous Load: 50 kVA at 0.9 power factor
sKVA = 50 kVA
sKW = 50 kVA x 0.9 power factor = 45 kW
Running kVA = 50 kVA
Running kW = 50 kVA x 0.9 power factor = 45 kW
System Totals:
sKVA = 795 + 75 + 50 = 920 kVA
sKW = 222.6 + 67.5 + 45 = 335.1 kW
Running kVA = 135.1 + 75 + 50 = 260.1 kW
Running kW = 123 + 67.5 + 45 = 235.5 kW
Alternator kW = 123 + 67.5 + 45 = 235.5 kW
Using one manufacturer's sizing software, the recommended generator set size is 350 kW. This
is based on about a 20% transient voltage dip followed by a sustained recovery of 90% of rated
voltage during starting. The generator would run at about 67% of capacity (Running kW = 236,
Generator Capacity = 350 kW, 236 / 350 = 67.4%).
Large motors that are started with across-the-line starters fed by generators to allow for very
low transient voltage drop during starting can require a greatly oversized generator set. In
these cases the running capacity of the generator can be significantly lower than the rating of
the generator set. It is critical to ensure that the running load represents at least 30% of the
rated size of the generator set or wet stacking or carboning can occur. See Part 7 for
definitions and a discussion of these terms.
Example #2: Motor with a solid-state starter with bypass contactor:
Motor Load: 150-hp, NEMA “F” motor with a 0.28 starting power factor
Running power factor of 0.91 and an efficiency of 0.91.
Soft Start set at a 300% full load ampere current limit. The current limiting range is
typically between 150% and 600%. A 300% current limit reduces the starting kVA and
starting kW by almost 50%.
sKVA, = (150 hp x 0.746 kW/hp) / 0.91 (efficiency) = 123.0 kW
10/24/2010 The importance of knowing the basics…
buyerzone.com/…/rbic-power-quality-… 2/5
123.0 kW / 0.91 (power factor) = 135.1 kVA = 162 amps @ 480-volt/
3 phase.
300 % current limit = 162 amps x 3 (3 x FLA) = 487 amps = 405 kVA
sKW = 405 kVA x 0.28 (starting power factor) = 113.4 kW
Running kVA = 123.0 kW / 0.91 (power factor) = 135.1 kVA
Running kW = (150 hp x 0.746 kW/hp) / 0.91 (Efficiency) = 123.0 kW
Lighting Load:75 kVA at 0.9 power factor
Starting kVA = 75 kVA
Starting kW = 75 kVA x 0.9 power factor = 67.5 kW
Running kVA = 75 kVA
Running kW = 75 kVA x 0.9 power factor = 67.5 kW
Miscellaneous Load: 50 kVA at 0.9 power factor
Starting kVA = 50 kVA
Starting kW = 50 kVA x 0.9 power factor = 45 kW
Running kVA = 50 kVA
Running kW = 50 kVA x 0.9 power factor = 45 kW
System Totals:
sKVA = 405+ 75 + 50 = 530 kVA
sKW = 113.4 + 67.5 + 45 = 225.9 kW
Running kVA = 135.1 + 75 + 50 = 260.1 kW
Running kW = 123 + 67.5 + 45 = 235.5 kW
Alternator kW = 123 + 67.5 + 45 = 235.5 kW
Using one manufacturer's sizing software, the recommended generator set size for this example
is 275 kW. This is based on about a 20% transient voltage dip followed by a sustained recovery
of 90% of rated voltage during starting.The generator would run at about 86% of capacity
(Running kW = 236, Generator Capacity = 275 kW, 236 / 275 = 85.8%).
At this threshold, the engineer may want to specify the next larger generator set to allow for
some future additional loads. It is clear from this example that reducing the sKW requirements of
the motor with the use of current limiting starters can reduce the size of the required generator
set.
The solid-state starter will cause voltage distortion across the alternator of the generator. This
distortion is cause by the nonlinear way the silicon-controlled rectifiers (SCRs) in the solid-state
starter draw current. The generators alternator may have to be oversized to compensate for
this voltage distortion. This issue can be avoided, as in the example above, by specifying a
bypass contactor with the sold state starter. The bypass contactor closes after startup and
the SCRs are only operating during the starting of the motor. If the solid-state starter does not
have a bypass contactor, a rule of thumb is to add again the motor running kW to the running
kW of the system. This calculation will estimate the total alternator kW. See calculation below:
Alternator kW with a bypass contactor: 235 kW
Alternator kW without a bypass contactor: 235 kW + 123 kW = 358 kW
If the soft starter does not have a bypass contactor, the engineer must determine if a larger
alternator is required. In our example above, the same 275-kW generator can handle either case
(with and without a bypass contactor), but a larger alternator is required to handle the
additional alternator kW if no bypass contactor is specified.
In our example above, in the across-the-line starter situation, the sKW drove the requirement
for the larger generator set. Below is a breakdown of some of the critical parameters for the
different starting methods as well as the two generator set sizes noted above. Three total
generator set configurations have been noted below, one for 350 kW and two for 275 kW. The
275-kW generator set has been split into a smaller and a larger alternator. The parameters
(sKVA, sKW and alternator kW) noted under the three generator set configurations are the
maximum the generator set can provide. The parameters noted under the form of motor starting
are the requirements for the different system examples noted above with their associated form
of motor starting configuration.
Chart 1
sKVA sKW Alternator kW
275 kW Genset w/ Small Alternator 1028 291 300
275 kW Genset w/ Larger Alternator 1372 293 380
350 kW Genset 1896 518 515
Solid-State Start with no Bypass 530 226 358**
Solid-State Start with Bypass 530 226 235
10/24/2010 The importance of knowing the basics…
buyerzone.com/…/rbic-power-quality-… 3/5
Across the Line Starter 920 335* 235
* The across-the-line starter exceeded the sKW (starting kW) capacity of the 275-kW
generator. Therefore, a 350 kW generator set is required.
** The solid state starter without a bypass contactor exceeded the alternator kW of the
smaller alternator. Therefore, a 275-kW generator set with a larger alternator is required
for this starting configuration.
Several factors should be evaluated prior to determining the type of starting for motors within
an electrical distribution system. These factors include, but are not limited to the following:
Electrical system effects from not providing some form of reduced voltage starting. How
will the large inrush current affect the components in the electrical distribution system?
A cost analysis of providing alternative forms of starting should be performed. It may be
more cost effective to provide a solid state starter, or other form of reduced voltage
starter, with a smaller generator set than to provide an across the line starter with a
larger generator set.
All applicable utility or jurisdictional requirements have to be evaluated during the design
process of the generator standby system.
In addition, the system designer must be familiar with local codes and the serving electrical
utility requirements. Many electrical utilities specify the largest system voltage drop during
motor starting or specify the largest motor size that can be started with an across the line
start.
For example, one of our local electrical utilities, Seattle City Light, indicates that “reduced
starting current shall be required on all motors exceeding 15 hp nameplate rating, unless
otherwise agreed to by the utility.” Another serving utility in our area, Puget Sound Energy,
indicates, “If the voltage dip exceeds 2%, the transformer size must be increased to reduce the
dip to 2%. The customer is responsible for the difference in cost of the larger transformer.”
When only the maximum allowable voltage dip is indicated as a requirement, the largest allowed
motor without some form of reduced voltage starting will be based on the size and impedance of
the serving utility transformer.
Another form of reduced-voltage starting is the variable-frequency drive. VFDs can reduce both
sKVA and sKW. They draw load in a nonlinear fashion, similar to the solid-state starter, and will
continue to draw loads in a nonlinear manner, as the frequency of the motor can be altered by
control devices through the entire operation of the motor. The size of a generator set feeding a
system with a VFD may have to be increased or may have to be fitted with an oversized
alternator similar to that of a system feeding a soft start without a bypass contactor. The use
of 12-pulse IGBTs (Insulated Gate Bipolar Transistor), (PWM) pulse width modulated drives and
harmonic filtering can make the VFD more generator-friendly.
In addition, stepping the sequence of the loads within the requirements of the National Electric
Code, Section 700 can greatly reduce the sizing of the generator set. Since larger generators
are often required because of the peak kW or kVA on the system, stepping the loads long
enough for the inrush of motors not to be simultaneous can reduce the ultimate size of the
generator set required to feed the critical loads.
Articles in This Series
Part 1: Sizing and Code Issues
Part 2: The Effects of Harmonics
Part 3: Complying with the Codes and Controlling Noise
Part 4: Fuel Configurations for Standby Gensets
Part 5: Paralleling Generators in Critical Applications
Part 6: Generator Sizing and UPS
Part 7: Commissioning, Training and Long-Term O&M Programs
Part 8: Basic Calculations for Sizing Generators and the Impacts of Certain Loads
Part 9: Design Criteria for Grounding
Part 10: Generators and the 2005 NEC
Ready to find a generator dealer for your business?
Consulting-Specifying Engineer is a practical, application-oriented
magazine that chronicles the changes sweeping across the
construction industry.
RelatedTerms
Diesel Generator, Commercial Generators, Emergency Generator, Equipment Leasing, Gas Generators,Generator Manufacturers, Generator Prices, Metal Buildings For Sale, Portable Generators, Used Generators,
Gas Turbine SalesAvon / Olympus - Alba Power TurbineExcellence - Scotland, UK
Renewable Energy InfoFind Out About Eco Energy Sources &How To Be Green. Get A Free Report!
Ads by Google
10/24/2010 The importance of knowing the basics…
buyerzone.com/…/rbic-power-quality-… 4/5
Forklift Telescopic, Telehandlers, Generator Buyer Comments
Corporate About Us - Help - Privacy Policy - Top Cats - Site Map - B2B Sales Leads - Affiliate Marketing Programs -Lead Generation Blog - Subscribe
Customer Care: 1-888-393-5000
© 1997-2010, BuyerZone.com, LLC, A Division of
blank
10/24/2010 The importance of knowing the basics…
buyerzone.com/…/rbic-power-quality-… 5/5