Genset Sizing

Required Information
Duty rating to be applied
Frequency (50Hz/60Hz)
Nominal Voltage
Climatic Conditions
Voltage and Frequency dip requirement
Load parameters
Mandatory load steps or sequence of load step, if they exist
Number of genset in parallel
Sizing software(Power-Suite)

Motor Load
AC electric motors represent inductive loads with
lagging power factors
Different types of motors have different starting
characteristics.
Starting characteristics may drive the need for a
larger or smaller generator.
Starting an electric motor can create voltage dips in
excess of 40% if the genset is not properly sized.

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alternator

Apparent pow er

kVAR =

Inductive Load: kW vs. KVars

kW = engine

k W Dem anded by Load

k Var Dem anded by Load

Inductive loads need two kinds of power to function properly:

Active power (kW) actually performs the work
Reactive power (kvar) maintains the electromagnetic fields

Engines Produce kW--Fuel Rate Controls

Alternators Make kVAR--Excitation Controls

Generator Transient Response to Step

Loads
Voltage

Alternator Must Support kVA:

Limit Initial Dip
Recover to Acceptable Voltage
(Motor Torque Proportional to
Voltage2)
Engine Must Support kW (Similar
to Voltage Response)
Dynamic Response Combination of
Frequency and Voltage

Frequency

Voltage Response at Constant Speed

We are going to create a project with PowerSuite with the

following criterias:

50Hz
400V
Min rated capacity 30%
18% Voltage Dip,
5% Frequency Dip
25C
150m

Differents types of loads

Electrical Motors
UPS
Lighting
Regenerative loads
Miscellaneous load

Apply Alternative Starting Methods on High

Inertia Loads With Caution

Okay for low inertia applications.

Watch out with high loads!

Motor Torque Proportional to

Applied (Voltage)2

Typical 3 Induction Motor

Characteristics
Current

High Locked Rotor Current

and KVA
Torque Shown for 100%
Rated Voltage (solid red line)
Starting (instantaneous) PF
0.2 to 0.4 for 3 Motors
Higher Starting
Requirements for High
Efficiency 3 and for 1
Treat Synchronous Motors
Like Induction Motors

Power Factor
1.0

Power

100

Motor Torque

POWER FACTOR (LAGGING)

Direct On-Line (DOL) Start

PERCENT TORQUE, POWER, CURRENT

600

0.2

Load Torque
0

20
40
60
80
PERCENT MOTOR RATED SPEED

100

Lets enter the following load with direct on line starting

method in Powersuite:

Motor Running Power (Electrical) = 300kWe, 350kVA

Starting kVA = 6 x 350kVA = 2100kVA
Starting kW = 2100kVA x 0.3 p.f. = 630kW

Star-delta Starting
Typical kW demand of motor

Reduced Starting Impact

Watch out for the transition
(kVA)
Potential start failure if
alternator cannot sustain
voltage in transition.

Typical kVA demand of motor

Transition on Reduced Voltage Starters

Same as DOL

Transition
too Early

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True Reduced
Voltage

We will now enter the following load with star/delta starting

method in PowerSuite:

Motor Running Power (Electrical) = 300kWe, 350kVA

Starting kVA = 3 x 350kVA = 1050kVA
Starting kW = 1050kVA x 0.3 p.f. = 315kW

Auto Transformer

This method uses transformer action to reduce the voltage applied to the motor
and current seen by the supply. An improved torque/amp ratio is achieved and
starting current is typically 3 x FLC, depending on the voltage tapping selected.
Normally the voltage is applied to the motor in voltage steps through the T/F
taps being selected through contactors. Typical tappings are 50%, 70%,
followed by full voltage being applied to the motor. The major disadvantages
are size & cost. Mechanical snatch at switch on is not controllable and may
cause problems. Once tappings have
been selected, it may be necessary to
change them according to changes in
load parameters.
Advantages

Simple operation

Disadvantages

Poor controllability

Bulky

Very Expensive

Soft Starters
Limit the starting current by limiting the amount of
starting torque.
Current distortion has to be considered for the non
linear loads.
Advantages: Less mechanical stress, reduced start
current, improved control of acceleration and
deceleration
Disadvantages:
Size & Cost

Uninterruptible Power Supply

UPS can produce high levels of
current distortion.
Excessive generator voltage
distortion
Increased Power System
Component losses and heating
Harmonics can be reduced by
filters on the UPS.

Phase Controlled Rectifiers: Voltage and

Current Distortion

3
(Or 18 Pulse)

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Lets enter the following UPS Load in PowerSuite

Rated Output= 200kVA
Rectifier= 12 Pulses

Lighting Loads
Fluorescent & Discharge
Both are non-linear loads which may need to be
considered when sizing your generator
Incandescent
Defined as a general load for sizing purposes

Lets enter the following lighting load in PowerSuite

Light Type : Fluorescent

Running KVA = 50kVA

Regenerative Load
Reverse power needs to be considered.

Regenerative Load
Stage 1:Genset Supplies Site Loads
Stage 2:Lift Motor Produces
Reverse Power 200kW
100kW Load Bank Removes
Risk of Reverse Power

Miscellaneous Loads

If the load is so specific that you can not find its kind in PowerSuite,
you can create your own kind of load

Lets enter the following load in PowerSuite

Running & Starting = 100 kW
Running Power factor= 0.95
Starting Power factor= 0.50

We are going to size the genset with a single load step and the load we
entered:
(In case a single genset is not enough to start the loads with the criterias
it is possible to add more gensets)

Size of genset optimization

Step Loading the Generator

Apply Load in Increments

Apply Large Motor Loads First

Limit Voltage and Frequency dip

Ultimately reduce genset size

Step Starting Sequence

Lets now optimise the genset size

Thank You
Questions?

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