Generator Protection Typical Schemes and L&T Solutions

1.0 With increasing complications in the power system, utility regulations , stress on cost reduction and
trend towards automation, Generator protection has become a high focus area. State of the art ,
microcontroller based protection schemes from L&T offer a range of solutions to customers to address
the basic protections and control requirements depending upon the size and plant requirements.
Generators - size less than 300 KVA

Normally these generators are controlled by MCCBs, which offer O/C and short circuit protections. It is
advisable to have following protections in addition to MCCB (Fig.1):
E/F protection (51N) : This will protect the generator from hazardous leakages and ensure operator
safety. Many SEBs have already made E/F protection as mandatory. L&T Relay for this is MC12A.

3.0 Generators - size 300 to 1 MVA

There are two major differences when compared with the small machines considered in section 2.0.
a) IDMT Over current + E/F relay will be required addition to normal MCCB or ACB releases - since
the generator may need shorter trip times for faults in the range 100% to 400% level. L&T Relay
MC61A will be the ideal choice.
b) By virtue of larger power level, any faults inside the stator or fault between the neutral of the
machine and the breaker terminals can reach very high intensity.
Such internal faults must be cleared instantaneously. Normal IDMT over current / E/F relays are not
adequate to monitor this internal fault condition. A separate relay scheme is required to monitor this
internal fault status - otherwise the machine can circulate very high fault currents resulting in severe
damage.
A high impedance differential relay scheme, with L&T relay SC14S (3 nos) is the best suited for this
purpose (Fig.2). If the neutral is formed inside the machine, the differential relay scheme will not be
possible - in this case a Restricted E/F scheme , with same SC14S relay (1 No.) is the solution. Care
should be taken to provide adequate no. of CTs as shown in the diagram.
c) Machines of this size are likely to have external controls for frequency and excitation - so that they

can be run in parallel with other power sources (other generators on the same bus or the local grid).
This necessitates voltage and frequency related protections as well. L&T Relays UM30A is the best
solution for this purpose. Alternately Relay MV12A (4 Nos) can be used if frequency protection is built
in the engine.

4.0 Generators - Size 1 MVA to 10 MVA

Being a medium sized generator, it will need more comprehensive protection both for the stator side
and the rotor side.
4.1 Stator side protections :

Voltage restrained Over Current Protection (50V / 51V) :

Normal IDMT O/C will not work here - when a over current fault occurs, due to higher current levels,
there would be a drop in terminal voltage. For the same fault impedance, the fault current will reduce
(with respect to terminal voltage) to a level below the pick up setting. Consequently normal IDMT may
not pick up. It is necessary to have a relay whose pick up setting will automatically reduce in proportion
to terminal voltage. Hence the over current protection must be voltage restrained. Two levels of Over
current protection is required - low set and highest ( for short circuit protection).
Thermal Overload (49) :

This protection is a must - it monitors the thermal status of machine for currents between 105% to the
low set O/C level ( normally 150%).
Current Unbalance (46) :

Generators are expected to feed unbalanced loads - whose level has to be monitored. If the
unbalance exceeds 20%, it may cause over heating of the windings. This heating will not be detected

by the thermal overload relay - since the phase currents will be well within limits. A two level
monitoring for unbalance is preferred - first level for alarm and the second level for trip.

Loss of excitation(40) :

Loss of excitation(40) : When excitation is lost in a running generator, it will draw reactive power from
the bus and get over heated. This condition is detected from the stator side CT inputs - by monitoring
the internal impedance level & position of the generator.
Reverse Power (32) : Generators of this size may operate in parallel with other sources, which may

cause reverse power flow at certain times ( during synchronization or when there is a PF change due
to load / grid fluctuation or when there is a prime mover failure). When reverse power happens, the
generator along with prime mover will undergo violent mechanical shock - hence reverse power
protection is absolute must.
Under power (37) : It may not be economical to run generators below a certain load level. This

protection will monitor the forward power ..4 -4- delivered by the machine and give alarm
when the level goes below a set point.
Under / Over Voltage (27 / 59 ) : This will protect the machine from abnormal voltage levels, particularly

during synchronization and load throw off conditions.

Under / Over frequency (81) : This will protect the machine from abnormal frequency levels, particularly

during synchronization and load throw off conditions. This will also help in load shedding schemes for
the generator.
Breaker Failure Protection : This protection detects the failure of breaker to open after receipt of trip

signal. Another trip contact is generated under breaker fail conditions , with which more drastic
measures (like engine stoppage, opening of bus coupler etc) can be taken.
Multifunction relay IM3GV from L&T, as a single unit protects the generator for all above listed faults (a)

to (h)- giving at the same time the benefit of small panel space, simple wiring and user friendly
operation.
Stator Earth fault (64S): L&T relay MC12A will do this job.
Differential Protection (87G) : This protection is very important - since the machines of this size have to

be protected for severe damages that may occur due to internal faults. Considering the large power
levels, it is necessary to have a percentage biased, low impedance differential relay - L&T's relay
MD32G is the ideal solution. MD32G has following advantages : - it provides percentage biased
differential protection with dual slope characteristics - it has a built in REF protection element (87N),
which will monitor the generator for internal earth faults. - It has a built in O/C protection, as a back up
PT Fuse Failure Protection : This relay will detect any blowing of PT secondary fuse - and give a

contact which can be used to block the under voltage trip. L&T relay PTF03, with less than 7 ms
response, will be ideal for this purpose.
4.2 Rotor side protections : Generators of this size, will need rotor side protections listed below :
a) Rotor Excitation Under Current : This is a DC under current relay ( UBC/A/37), which will monitor the

excitation current.
b) Rotor Excitation U/V(80) : This is a DC under voltage relay (UBC /80), which will monitor rotor

voltage.
c) Diode failure Relay : Brushless excitation systems will have rotor mounted diodes, which can

become short or open during operation. Diode Failure relay (RHS) will monitor the condition of these
diodes , for both open circuit and short, and give alarm.
d) Rotor Earth Fault(64R) : Relay UBO/CR will monitor the rotor winding status for the Earth fault.

Please see Fig 3 for the scheme with relays as above.

5.0 Generators above 10 MVA

For large generators above 10 MVA size, the philosophy of main protection and back up protection
has to be followed. In addition to the protections listed in Section 4.0, following extra protections are to
be considered:
a) 100% Earth Fault Protection : This will help in sensing earth faults close to neutral.
b) Inadvertent Breaker Closure : This will avoid closing of generator to bus during coasting to stop, or

when stand still or before synchronism.

c) Under Impedance : This will be required as a back up protection for the whole system including the

generator transformer and the associated transmission line. If the distance relay fails to pick for some
reason, this under impedance function will pick up and save the generator.
d) Over Excitation : This will protect the generator from Over fluxing conditions.

Please see Fig. 4 for the SLD.

6.0 Generator connected in parallel to grid : Whenever generators are running parallel to grid, a

comprehensive Auto Synchronising & Grid Islanding Scheme will be required. This scheme will help in
synchronizing the generator to the bus and opening the incomer breaker of the plant whenever there is
a severe grid disturbance, thus protecting the generator from ill effects of disturbed grid. L&T Relays
SPM21, UFD34 , MW33 and MRP11 are ideal for this scheme. Please see Fig. 5.

R.Seshadri
7.0 Generators connected in parallel on a common bus : Whenever more than one generator is

operating in parallel , it is necessary to see that the plant load is equally shared by the generators in
parallel. If there is unequal sharing, there would severe hunting amongst the generators and
eventually this will lead to cascaded tripping of all generators, causing a total black out. L&T relays
RRS (two relays per generator) provide the most effective, online load sharing system for generators
in parallel. Please see Fig 6 for a representative scheme of load sharing for three generators.

8.0 Summary : The sections above describe the actual requirements and various options available from

L&T towards protection and management of generators of various sizes. For generators above 1 MVA
size, it is also recommended to have complete data acquisition & control through PC. L&T supplies
MSCOM software for this purpose. The relays like IM3GV, MG30, MD32T,UM30A can all
communicate to a PC and provide all management data.
A comprehensive scheme as shown below will be the most desirable one.

Forum
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Home > Basics > Sizing Gen-Sets For Large Motor Starting
Sizing Gen-Sets For Large Motor Starting
Feb 1, 2000 Larry A. Bey, Cummins Onan Corp. | Electrical Construction and Maintenance

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Remember, an on-site engine-generator set is a limited source of power, both in horsepower available
from the engine, and kVA available from the generator. As such, it must be large enough to start as well

as run connected motor loads. You've lost normal power. Your engine-generator set (gen-set) starts up
and reaches speed. Now, you want to start some large motors key to your operation. Suddenly,
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Sizing Gen-Sets For Large Motor Starting
Feb 1, 2008 12:00 PM, By Larry A. Bey, Cummins Onan Corp.
Remember, an on-site engine-generator set is a limited source of power, both in horsepower available
from the engine, and kVA available from the generator. As such, it must be large enough to start as well
as run connected motor loads.
You've lost normal power. Your engine-generator set (gen-set) starts up and reaches speed. Now, you
want to start some large motors key to your operation. Suddenly, starter holding coils drop out, starter
contacts chatter, and a few motors stall due to insufficient torque for acceleration. Can this happen to
you? It sure can, if you haven't sized your gen-set properly.
We all know that motors draw a high inrush current during starting:typically six times full load current.
But, inrush currents for the high-efficient motors specified today are almost double that amount.
Motors with high inertia loads can also require up to three times rated power during starting.
Yes, it's common for motor starting kVA requirements to determine the size of the set. However, the
following factors also play a key role in sizing gen-sets:
Harmonics caused by variable frequency drives.
Use of high-efficiency motors.
Sequential starting of motors.
What's involved. When starting motors, large voltage and frequency dips may occur if the generator set
isn't sized properly. Other loads connected to the generator output may be more sensitive to voltage
and frequency dips than the motor or motor starter, and this may cause problems. For example, a rate
of change greater than 1 Hz/sec in generator frequency may cause some static UPS units to malfunction.
If the load on the generator set is a single large motor, particularly one requiring high starting torque, a
number of problems can occur. They include: sustained low-voltage operation that can cause
overheating; extended load acceleration times; opening of circuit breakers or motor protective devices;
engine-generator protection shutdowns; and more.
Your gen-set's ability to start large motors without excessive voltage and frequency dip is a function of
the complete system. This includes:
The engine power available;
The generator's capacity;

The response of the generator excitation system;

The energy stored in the rotating inertia of the gen-set; and
The acceleration of the motor and its load.
You must consider all these factors for proper gen-set sizing. Here's a simple rule for estimating the size
of an engine-generator set for motor starting: 1kW of generator set rating per each 3/4 to 1 hp of motor
nameplate.
Let's look more closely at a motor start. Induction motors have typical starting characteristics. The curve
of motor current versus speed shows that during starting, the motor draws approximately six times its
full load current; this current remains high until the motor reaches about 80% of speed. This high inrush
current causes a dip in generator voltage. The electric power initially required by the motor (with the
motor at standstill) is about 150% of rated power. The power required by the motor peaks at about
300% of rated power and 80% of speed with full voltage applied. But, the generator set supplies less
than 300% power because starting voltage is lower than full voltage during acceleration, and because
the generator set's rotating inertia transfers energy to the motor.
The motor must develop greater torque than required by the load. The motor's torque curve at full
voltage is above the load's torque curve. The difference between the torque developed by motor and
the torque required by the load determines the rate of acceleration. Since torque is proportional to
voltage, any reduction in voltage means a proportional reduction in torque.
A properly sized generator set will support the high starting kVA requirements of the motor, and
maintain sufficient output voltage for the motor, so it can develop adequate torque to accelerate the
load to rated speed.
All standby gen-sets use synchronous generators with exciters. Many are available with permanent
magnet generator (PMG) excitation systems. The PMG provides excitation power independent of the
generator terminal voltage. As such, it can maintain full excitation:even during transient loading, such as
motor starting. Full excitation power results in a less extensive voltage dip and improved recovery times.
Using reduced-voltage starting. Though a voltage dip often causes various problems, a controlled
reduction in voltage at motor terminals can be beneficial, but only when reduction in motor torque is
acceptable. Reducing motor starting kVA can reduce the required size of the gen-set, reduce the voltage
dip, and provide a softer start for the motor loads. When sizing gen-sets, you must first determine the
acceptable level of motor torque required during starting, or the loads will accelerate slowly, or even fail
to reach full speed:ultimately causing motor damage.
Using solid-state starters. Solid-state starters can adjust the starting torque, acceleration ramp time, and
current limit for controlled acceleration of a motor when it starts. For the purpose of sizing a gen-set,
the current limit adjustment reduces the inrush current and may be used to reduce the starting kW and
kVA requirement on the generator. The range of available current limit settings is typically from 150% to
600% of full-load current. A 600% current limit setting on the solid-state starter results in a gen-set

sizing that's the same as an across-the-line starting. A 300% current limit setting reduces starting kVA by
50%.
Use of the current limit setting also reduces motor torque available to the load. From a gen-set sizing
perspective, an extended acceleration ramp time and low current limit setting (if appropriate for the
motor and the mechanical load) would result in the least voltage and frequency excursions.
One downside to using solid-state motor starters is their integral SCRs (silicon-controlled rectifiers) will
cause voltage distortion. To compensate, you'll have to oversize the generator. The recommendation:
two times the running kW load, except where you're using an automatic bypass. If the solid-state starter
does have an automatic bypass, the SCRs are only in the circuit during starting. Once the motor is
running, the bypass contactor closes and shunts the SCRs. In this case, you can ignore the voltage
distortion during starting, and you don't have to add generator capacity.
VFDs require larger generators. All versions of variable frequency drives (VFDs) are current limiting and
reduce starting kW and kVA. The current drawn by these drives is nonlinear (having harmonics), which
causes a distorted voltage drop across the reactance of the generator. Since VFDs are nonlinear, you
must include an additional generator capacity sizing factor to keep voltage distortion to a reasonable
level of approximately 15% total harmonic distortion (THD) or less. The larger the generator, the greater
the reduction in impedance of the power source (generator), which in turn, reduces the effects caused
by harmonic current distortion.
For six-pulse VFDs, a typical generator sizing factor would be twice the running kW of the drive. This
offsets any reduction in starting kW and kVA. If it is the pulse width modulated (PWM) type (or includes
an input filter to limit current distortion to less than 10%), then you can reduce the sizing factor down to
1.4 times the running kW of the drive.
Using a step starting sequence. The starting sequence of loads can have a significant effect on the size of
a gen-set. One commonly used approach is to assume all connected loads will start in a single step. This
results in the largest gen-set selection. Unless you do something to add load incrementally (such as
multiple transfer switches with staggered time delays, or a step load controller), then you should use a
single-step load for sizing purposes.
In multiple step applications, you start the largest motor first, to minimize the gen-set size. Once placing
all loads on line with the gen-set, you can stop and start load equipment with automatic controls. Here,
you'll have to size the gen-set by assuming the largest motor starts last, with all other connected loads
already on line.
Examples of sizing gen-sets. You can size a gen-set with manual calculations (using a worksheet) or with
PC software available from most major gen-set manufacturers. The basic process is the same. It's always
best to use actual data (if known).
If this information isn't available, using PC software is the best option, since much of the required
information on typical load characteristics is available as default information. If you use the manual

sizing procedure, it should result in a recovery voltage of at least 90% of rated voltage and a starting
instantaneous voltage dip of approximately 20% to 40%.
The instantaneous voltage dip and frequency dip will likely vary from manufacturer to manufacturer,
based on equal ratings of gen-sets. For a closer estimation of transient (starting instantaneous voltage)
performance, use the manufacturer's sizing software.
Using the manual sizing procedure.
Step 1: Gather information. You'll need to know the following for each motor load:
Nameplate hp,
Running kilowatts (RkW),
Running kilovolt-amperes (RkVA),
Running motor power factor (PF),
Starting motor PF, and
Locked rotor kVA/hp.
You can use the following equation to calculate RkW and RkVA for motors: RkW = [(Nameplate hp) x
(0.746kW/hp)] / Efficiency (eq. 1)
RkVA = RkW / Running motor PF (eq. 2)
To calculate starting kilovolt-amperes (SkVA) and starting kilowatts (SkW) for motors, use these
equations:
SkVA = (Nameplate hp) x (Locked rotor kVA/hp) (eq. 3)
SkW = (SkVA) x (Starting motor PF) (eq. 4)
Step 2: Total the RkW, RkVA, SkW, and SkVA numbers for all the loads.
Step 3: Select the gen-set by comparing the RkW, RkVA, SkW, and SkVA to the ratings on the
manufacturer's specification sheets (after appropriate derating for ambient temperature and altitude).
Example One calculation. Determine gen-set size for three loads started across-the-line in a single step.
Here's pertinent information:
Two 200 hp motors, Code G, 92% running efficiency, 0.25 starting PF, 0.91 running PF.
Total 100kVA of fluorescent lighting, starting PF of 0.95, and running PF of 0.95 (Note: We're using the
terms starting and running PF for the lighting load here for clarification when adding the motor loads.
Actually, the ballast for the lighting load has a constant PF of 0.95.)

Step 1: Information gathering and calculations. 200 HP motor:

RkW = (200 hp x 0.746 kW/hp) / 0.92 = 162.2kW
RkVA = 162.2kW / 0.91 PF = 178.2kVA
SkVA = 200 hp x 5.9 kVA/hp41180kVA
SkW = 1180kVA x 0.25 PF = 295kW
Florescent Lighting:
RkW = 100kVA x 0.95 PF = 95kW
RkVA = 100kVA
SkVA = 100kVA
SkW = 100kVA x 0.95 PF = 95kW
Step 2: Totals.
Load.......... | RkW | RkVA | SkW | SkVA
200hp Motor | 162.2 | 178.2 | 295 | 1180
200hp Motor | 162.2 | 178.2 | 295 | 1180
Lighting....... | 95.... | 100... | 95. | 100
Totals (kVA). | 420... | 457.. | 685 | 2460
Step 3: Selection. At a minimum, you'll have to size the gen-set to supply the maximum starting (surge)
demands and the steady-state running loads of the connected load equipment. In this example (using
one manufacturer's published data), you would select a 750kW generator set with 2944 SkVA available
at 90% recovery voltage to supply the total load SkVA of 2460. The load totals for RkW, RkVA, and SkW
are well within the rating of the 750kW (938kVA) gen-set you selected. The running kilowatt load of
420kW is 56% of the 750kW gen-set standby rating.
Example Two calculation. Assume you have the same three loads as in Example One, but now you're
using an autotransformer type reduced voltage starter that is set at the 65% starting voltage to start the
two motors. This tap setting will reduce the starting kVA by the square of the voltage (0.65)squared, or
0.42 times the starting kVA.
Step 1: Calculations
200 HP motor:
RkW = (200 hp x 0.746 kW/hp) / 0.92 = 162.2kW

RkVA = 162.2kW / 0.91 PF = 178.2kVA

SkVA = 200 hp x 5.9 kVA/hp = 1180 x (0.65)squared = 495kVA
SkW = 495kVA x 0.25 PF = 124kW
Florescent Lighting:
RkW = 100kVA x 0.95 PF = 95kW
RkVA = 100kVA
SkVA = 100kVA
SkW = 100kVA x 0.95 PF = 95kW
Step 2: Totals
Load.......... | RkW.. | RkVA | SkW | SkVA
200hp Motor | 162.2 | 178.2. | 124. | 495
200hp Motor | 162.2 | 178.2. | 124. | 495
Lighting...... | 95..... | 100... | 95... | 100
Totals (kVA) | 420... | 457... | 343. | 1090
Step 3: Selection. Using one manufacturer's published data, you would select a 450kW gen-set to supply
the required starting kVA. The running kilowatt load of 420kW is 93% of the gen-set's standby rating. So,
if you want a margin for future load additions, you would select a 500kW gen-set running at 84% of
rated standby power.

Sidebar: Here's What Causes Dip in Starting Voltage

When you start a motor across-the-line with a gen-set, the motor represents a low impedance load
while at locked rotor or stalled condition. This causes a high inrush current. The high motor inrush
current (I ms) flows through the generator armature windings and is affected by the reactance. This
causes a drop in generator voltage. Impedance controls the flow of current in AC circuits. But, the
generator armature reactance is such a large part of its total impedance that resistance is ignored.
The generator terminal voltage drops instantaneously when the motor starter contacts close at time
t40, as a function of the subtransient reactance (X"d). Generally, the larger the generator, the lower its
reactance. So, one way to minimize the instantaneous voltage dip is to increase the generator size.

The generator terminal voltage may drop further, depending on response of the generator's automatic
voltage regulator and the power capability of the excitation system. (Most gen-set automatic voltage
regulators include underfrequency protection.)
During momentary overloads, the engine speed may also dip. If it does, the automatic voltage regulator
reduces excitation power to the main field, which lowers the generator terminal voltage. This, in turn,
reduces the load on the engine, allowing it to recover to rated speed. Typically, a maximum generator
terminal voltage dip of 30% will not cause coils to drop out. (This allows for approximately 5% additional
voltage drop in the conductors between the generator and the motor).
Although the voltage dip, due to under frequency protection, may extend the voltage recovery time, it
also allows the engine to be sized closer to the steady-state running load rather than starting load. This
is particularly important with diesel engines, which should not run for an extended duration at less than
30% of rated load. (Extended light-load operation of a diesel engine can result in the accumulation of
unburned fuel in the exhaust system, due to incomplete combustion from low combustion
temperatures, called wet stacking. Light load operation can also result in engine damage from fuel and
water contaminating lubricating oil.)
After the initial voltage dip, it's important the generator restore voltage to a minimum of 90%-rated
value while supplying the motor starting kVA. At least 90% recovery voltage is necessary for the motor
to develop adequate torque to accelerate its load to rated speed.
A motor starting a high starting torque load, such as a loaded compressor, requires higher recovery
voltage than one starting an unloaded compressor. As the motor comes up to speed, the voltage will
rise, as the starting kVA input decreases. Once the motor is up to speed, the voltage should return to
rated value, if the gen-set is sized properly.

Sidebar: How Inertia Affects Gen-Set Sizing

The moment of inertia of a rotating mass offers resistance to acceleration. The load connected to the
motor shaft has its moment of inertia, and in practical situations for specific equipment, this may or may
not be available information.
Fortunately, for the purpose of sizing a gen-set, or more specifically to determine the engine power
needed to start and accelerate a rotating motor load, the motor load's moment of inertia need only be
broadly categorized as low or high inertia.
High inertia loads are characterized by high breakaway torque requiring prolonged acceleration. Low
inertia loads are characterized by low starting torque at standstill, with increasing torque as motor
speed increases resulting in rapid acceleration to rated speed.

Starting low inertia loads will reduce the normal starting kW needed. Look for more information on this
is in the sample calculations within this article.

Sidebar: Examples of High and Low Inertia

High inertia loads include:
Single- and multi-cylinder pumps
Single -and multi-cylinder compressors without unloading valves
Crushers
Hydraulic elevators without unloading valves
Low inertia loads include:
Fans, centrifugal and blower
Compressors starting unloaded
Centrifugal pumps
Motor-generator elevators
Note: Pumps starting into high head pressure and large diameter fans or fans starting into high
restriction areas should be classified as high inertia loads.
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Discuss this Article 3

Lee Chee Seng (not verified)

on Jul 4, 2012
Dear Sirs, I appreciate if someone could enlighten me by providing a recommendation of a suitable
genset size for an exercise as follows:- What would be the right size of genset for starting a 220KW
water pump motor by auto-trans method with a voltage dip limitation of not more than 15%. Thank you
for assisting. Best regards / Lee Chee Seng
Log In or Register to post comments

Anonymous (not verified)

on Jul 19, 2012
very helpfull Many diesel Generator Sales people are blank about the start up power of motors. And am
battling to select the correct size of generator.
Log In or Register to post comments

Anonymous (not verified)

on Nov 26, 2013
I did it with an Woodward easygen-3500 controller using the ramp up feature
Log In or Register to post comments

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Industry Resources // Electrical Engineering Resource Center // Understanding Generator Set Ratings
Print Version

UNDERSTANDING GENERATOR SET RATINGS

Generator set ratings may seem complex, but their basic purpose is simple: fit the customers
needs at the optimum reliability, performance, and cost. An improper rating means a
customer either buys more capacity than needed or risks shorter life to overhaul, more
repairs, and more downtime. Read more to learn how smart rating choices combined with the
latest in onsite power generation systems can help engineers match equipment to their
customers applications for optimal long-term performance.

UNDERSTANDING EQUIPMENT APPLICATIONS AND CAPABILITIES

CALL NOW TO LEARN MORE

Available ratings have changed in recent years, and more sophisticated switchgear can be
integrated with generator sets. That means more flexibility to specify generating systems that
closely match users requirements. The key to choosing the right rating is to understand the
application in detail. That means knowing the type of duty and answering several key
questions:

Neal Reinhardt
865-595-1034 or 865-7711036
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What is the average load factor?

What is the maximum required load?
How many hours per year will the generator sets run?
Will the generator sets be run isolated from or in parallel with the utility?

RATINGS DEFINED
Caterpillar defines five basic generator set ratings:

Standby
Emergency Standby Power (ESP)
Mission Critical Standby
Prime
Continuous

Cat generator set ratings differ in certain respects from those defined by the industry
standard ISO 8528-1. Basic descriptions of the Caterpillar genset ratings are offered below.
STANDBY RATING
In this application, the generator set is capable of providing emergency backup power at the
nameplate rating for the duration of an outage.
The average load factor of a Standby rated generator set should be no more than 70% of the
nameplate rating and applied to varying loads. A Standby generator set can run for a
maximum of 500 hours per year. The normal standby rating is not for use in utility paralleling
applications. For example, a 3 MW standby rated generator set will provide power for the
duration of an outage. It should be run for up to 500 hours per year and have an average
load factor of 2.1 MW.
EMERGENCY STANDBY POWER (ESP) RATING
The ESP rating differs from the Standby rating only in the number of running hours allowed
per year. ESP ratings allow a maximum running time of 200 hours per year at a 70% average
load factor with varying load.

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CATERPILLAR GENERATOR
SET RATINGS GUIDE
For Caterpillar diesel and
gas-powered generator
sets, 60Hz and 50Hz. (PDF
672KB)
CATERPILLAR GENERATOR
SET RATINGS DEFINITIONS
Get more details about the
ratings definitions for
Caterpillar diesel generator
sets. (PDF 28KB)
POWER SYSTEMS WHITE
PAPER: A HOLISTIC VIEW ON
GENERATOR SET RATINGS
Learn more about the
factors to be considered
when selecting a particular
rating for a given
application. (PDF 80KB)
CATERPILLAR GENERATOR
SET SPECIFICATION SHEETS
View specification sheets
for your diesel generator
set applications at Cat's
website.
CONTACT A SALES REP
Find a Power Systems
rental application specialist
by entering your ZIP code.

MISSION CRITICAL STANDBY RATING

In this application, the generator set is capable of providing emergency backup power at the
nameplate rating for the duration of an outage. The average load factor of a mission critical
standby rated generator set should be no more than 85% of the nameplate rating with
varying loads. A mission critical standby generator set can run for a maximum of 500 hours
per year.
Typical peak demand is 100% of the rating for maximum of 5% of the operating time. The
mission critical standby rating is not for use in utility paralleling applications. For example, a 3
MW mission critical standby rated generator set will provide power for the duration of an
outage. It should be run for up to 500 hours per year and have an average load factor of up
to 2.55 MW.
PRIME RATING
In this application, the generator set is capable of providing power to a varying load for an
unlimited number of hours per year. A Prime rated generator set is capable of providing full
nameplate rating for a period of time, but must have an average load factor of no more than
70% of the Prime rating. Ten percent overload is allowed for emergencies for a maximum of
one hour in 12, and for no more than 25 hours per year. The standard prime rating is for use
in either utility paralleling or isolated applications.
For example, a 2.7 MW rated unit may provide the full nameplate rating for a short duration,
but should have a maximum average load of 1.89 MW (not including generator set nonrunning time per ISO8528-1). The generator set can also provide 3 MW of power in
emergencies as defined above. An example of the Prime rating is shown in Chart 3.
LOAD MANAGEMENT RATING
The Load Management rating is simply a special application of the Prime rating. A Prime
rated generator applied under load management guidelines allows for a Prime rated
generator set to be used in parallel with the utility.
A Prime rated generator set under load management guidelines can run for a maximum of
500 hours per year. This generator set has the same nameplate rating as a Prime rated unit,
but allows for an average load factor of up to 100%. The Prime rating with load management
guidelines does not allow for a 10% overload capability. For example, these guidelines state
that a 2.7 MW unit (same nameplate rating as the Prime rated unit) can be run at 2.7 MW for
a maximum of 500 hours.
There are two basic load management practices: base loading and peak shaving. In base
loading, the generator set operates at a fixed kW output, and the utility provides power for
any peaks above that level. In this scenario the end user may export power to the grid if more
power is being generated then is required by the facility loads, and the appropriate
agreements with the utility are in place.
CONTINUOUS RATING
In this application, the generator set is able to provide power to a non-varying load for an
unlimited number of hours per year. The average power output of the generator set is 70% to
100% of the rating. The rating is designed to provide 100% of the rating for 100% of the
operating hours.
Typical Continuous rating applications include base loading in parallel with the utility and
cogeneration operations. An example of a Continuous rated generator set is shown in Chart
6.
PERFORMING DUAL DUTY

Intelligent use of ratings also can help your customers use power systems for the added
purpose of load management. Here, advanced switchgear is part of the equation.
Customers often want to use backup generators for load management to produce an
additional return on their investment. However, standby rated generator sets are not intended
for operation in parallel with the utility. To perform utility paralleling applications a prime rating
with load management guidelines or a continuous rated unit are appropriate.
Paralleling switchgear combined with the correct prime rated units is required when operating
under load management guidelines. The switchgear controls provide increased system
flexibility allowing generator sets to operate in parallel with the utility. The switchgear is able
to control the load on the generator sets and monitor the power supplied from the utility. This
ensures that the generator sets are providing the proper load and are not operating outside of
their rating guidelines.
WANT TO DISCUSS THIS SOME MORE?
Regardless of the application, generator set ratings help ensure that your customers power
needs are met and that generating equipment is protected from premature wear. Choosing
the right rating means making the proper tradeoffs between run hours, peak load, and
average load. The proper rating means the customer receives the optimum combination of
installed cost and long-term cost of ownership.
Stowers' Power Systems sales staff understands these generator set ratings and is well
positioned to assist with rating choices and act as a safe source of information for supporting
the entire power system.
Contact your Stowers Power Systems Sales Representative for more information on
choosing the best rating for your project.

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SKVA AND MOTOR STARTING

Generator sets are typically evaluated on the basis of their ability to start electric motors
and accelerate them to rated speed. Although there is a generally accepted standard for
this measurement, some manufacturers refer to a standard based on sustained voltage
dip, while other industry leaders measure the instantaneous voltage dip. Since there is
no direct relationship between sustained and instantaneous voltage dip, a comparison
between the two may be misleading. Below is an explanation.
MOTOR STARTING CAPABILITY
Generator sets are typically evaluated on the basis of their ability to start electric motors and accelerate them to rated
speed. Regardless of whether the motor has a load on it or not, starting it requires kVA far in excess of the motors
normal running kVA demand. The motor starting capability, measured in terms of starting kilovolt-amperes (sKVA), is
an indication of a generator sets ability to start motors with minimal drop in voltage. When a generator is coupled to a
synchronous driver (i.e., a nonslip motor tied to utility power), a generator voltage dip of 30% maximum is generally
acceptable (20% in many applications). The voltage will recover to within 2% of normal voltage as soon as the motor has
accelerated to rated speed normally about one second, or 60 electrical cycles. Due to engine lug, diesel-powered
recovery is longer but still occurs within seconds. The higher a generators sKVA for a given voltage dip, the better the
generator for motor starting.
SUSTAINED VOLTAGE DIP VERSUS INSTANTANEOUS VOLTAGE DIP
Although there is a generally accepted standard for how motor starting capability is measured, some manufacturers refer
to a sustained voltage dip value, which they explain as being the undervoltage which occurs for some period after motor
starting commences. However, this value fails to quantify the absolute instantaneous voltage dip experienced during
motor starting. Further, the method of calculating the value of sustained dip is largely undefined and does not account for
the fact modern voltage regulators will most always return a generator to rated voltage after motor starting (assuming the
engine can overcome the load).
Other industry leaders measure the minimum voltage immediately after the motor is switched on, known as the
instantaneous voltage dip. This method assures that the actual absolute value of voltage dip is presented and
generator starting capability is truly understood.
SIMPLE COMPARISONS MAY BE MISLEADING
This issue is further complicated by the fact that there is not likely to be a direct relationship between a sustained and
instantaneous voltage dip, so a simple comparison between the two may be misleading. The difference in the
methodology used for presenting motor starting capability between various manufacturers of generator sets must be
considered when developing specifications. Simply specifying an sKVA value may no longer be enough to preclude
misapplication in the field. Therefore absolute instantaneous voltage dip values should be utilized to ensure adequate
support of sensitive loads.

neutral grounding in parallel connected gensets

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11-02-2014 12:22 AM
hi all,
There is 4nos. 3.3kV, 2000kVA gensets which is parallel connected. all of its neutrals are grounded individually
without NGR, and each gensets are provided with e/f protection by neutral cts in the neutral to ground cable. but i
seen most of the systems are usually grounding only one geset neutral. my question if only genset is grounded, how
the rest of the gensets will be protected from earth fault, please share you valuable knowledge. see the attached
sketch for the present system design. thanks.

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Anonymous Poster

DG set sizing
10/06/2007 12:39 AM
is derating required while calculating
sizing of DG set? if yes then what type
of derating?

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#4 "Everything you always wondered about DG sizing !!!!" by

PetroPower on 10/07/2007 7:31 AM (score 1)
nesubra
Guru

#1
Re: DG set sizing
10/06/2007 3:59 AM

Join Date: Nov 2006

Posts: 679
Good Answers: 2

You need to arrive at the rating of the

set first after detailed study of the load
and using the diversity factor etc.
Derating is done depending upon the
engine and alternator's manufacturers
recomendation like higher altitude >
1000 m above sea level, higher ambient
temp etc.So deratng is done depending
upon other conditions and not while
arriving at the rating.
__________________
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nothing,be nothing
Reply

Samak
Commentator

#2
In reply to #1
Re: DG set sizing
10/06/2007 6:43 PM
By the way, what is the difference
between standby and continuous power
rating?

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Location: Alexandria,
Egypt

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Posts: 88
Good Answers: 1

skippy
Associate

#3
In reply to #2
Re: DG set sizing

Join Date: Mar 2007

Posts: 30

10/07/2007 2:11 AM

Good Answers: 2

Continuous rating is 100% of the gen set

( for both engine and alternator),
Standby is 110% for one hour in 12.
__________________
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PetroPower
Guru

#4
Everything you always wondered
about DG sizing !!!!
10/07/2007 7:31 AM

Join Date: Jan 2007

Location: Sitting
directly behind my
keyboard in
Albuquerque - USA
Posts: 592
Good Answers: 19

Derating is required for engine and a

little bit also for alternator for altitude,
temperature and a small bit for
humidity (not much). Approximately 3%
per each 300 m above 300 m for small
units about 100 kW (125 kVA) or less
and larger units may be rated for 1500
m before derating occurs. There is no
standard supplier trade name for their
ratings so you must ask the supplier for
the " (Rated) output at the generator
terminals with all parasitic losses and
derating factors for X * C, X % RH and X
altitude considering recommended
coolant for - x * C freeze protection and
/ or + x*C boiling point rise with 20%
fouling factor for water-cooled
components". To fill in the (rated) space
above consider the following:
Rating trade name terms are varied
between supplier and confusing so you
can't easily compare. Use one of the 3
following generally recognised terms to
fill in the (Rated) space above:
* Continuous uninterrupted duty
* Prime power base load
* Emergency standby
These are defined below after you read
the "understanding" comments.
The key is to get the supplier's
definitions of their ratings and apply it
to your load profile. Rating Definitions
are standardised by ISO 3046 and
others. Here is small generator set
example. Here is a large generator set
example (look at the last page).
Confusing, but not when you put your

load definition in writing and have the

supplier explain their terminology. Just
ask for ISO 3046 definitions to be
submitted with the offer.
Understand these things first:
Engines need oxygen and there is less
oxygen at high altitude so one cannot
put as much fuel with the thin air and
hence power is less requiring a larger
engine for the same power at sea level.
Most larger engines have turbochargers
which is a type of air pump that helps
overcome altitude losses. The
turbocharger compressed air is bloody
hot so it must be cooled by an
aftercooler. So some engines have
models followed by T (turbo) and A
(aftercooled).
Air density is less at altitude and fan
cooled things are less efficient by 3%
per each 300 m such as the cooling
radiator fan and also the generator
cooling fan. This is often overlooked. If
the engine is air cooled this must be
considered also.
Air is less dense with high temperatures
and the oxygen content is slightly less so
there is minor power and cooling
deratings for high ambient temperature.
Humidity displaces oxygen but this
derating is very very minor and not
normally a factor. It is more of a factor
for fungus growth on generator
windings and junction boxes.
Engine cooling systems need corrosion
protection, freeze protection and

boiling point raised by use of chemicals,

normally ethylene glycol. Glycol doesn't
remove heat and give it off as efficiently
as straight water so radiator derating
and aftercooler derating is required if
the aftercooler is using engine water as
a coolant. Do not ever run engines with
straight water, ever. The inside will
corrode and the water will boil. 3 mm of
corrosion has as much insulation as 40
mm of solid cast iron so heat will not
arrive to the water if there are scale
deposits inside.
Large DG engine pistons are cooled by
lube oil sprayed under the crown, so
high load heats up the piston and also
the lube oil. Some rating allow overload
for an hour followed by an hour at
lesser load. This is to give the lube oil a
chance to cool off.
Generators (alternators) have
temperature rise ratings; i.e. how hot
will the windings get at that load. The
lower the rise, the more copper, the
most money, the longest life. So a
generator rated for 500 kW and 80* C
rise above 50* C ambient will have more
copper than a generator rated 500 kW
and 120* C rise above 50* C ambient. In
USA we tend to rate DGs in kW.
Everywhere else they use kVA. The
power factor is considered as 0.8
average so outside USA those suppliers
assume 0.8 PF and report the kVA in this
way. So a 100 kW at 0.8 PF is a 125 kVA
machine. The definition of power factor
is too complicated for this already long
post.

Rating definitions:
ISO 3046 makes things complicated for
common people to understand. They
give engineering conditions not to
exceed. Basically:
"Continuous Uninterrupted" is that load
for 24/7 not one drop in load below the
rating. This rating is so conservative one
can overload the machine by up to
120% for a few minutes, and 110% for
an hour. The generator will likely be
rated for 80* C rise (more copper)
"Prime Base Load" is that load for 24/7
but the load will fluctuate lower and
allow the oil to cool off. So if you know
your building load is 1000 kVA worst
case with all the ACs switched on and
the kitchen fully switched on, etc., but,
in reality the load is 80% one day and
90% the next and during each day it
fluctuates up and down you do not need
a 'Continuous Duty' machine. For prime
base load the generator will likely be a
105* C rise ( a little less copper than
above). Overload of 110% for an hour is
allowed.
"Emergency Stand-By or Intermittent"
This is the highest rating and has no
reserve. It is meant for support of
power failures that do not exceed a few
hours in length. Most people do not try
to run the whole building when the
power fails and the suppliers know this.
These machines have very few hours on
them in a year so the customer receives
good value for the intended purpose. If
you used this rating for a 24/7
continuous uninterrupted duty the

engine and generator would need

overhaul every 6 months, instead of
every 10 years. The generator will likely
be a 130* C rise unit. The smallest
amount of copper compared to above.
__________________
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#4 "Everything you always wondered about DG sizing !!!!" by
PetroPower on 10/07/2007 7:31 AM (score 1)
nesubra; PetroPow er; Samak; s

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Questionnaire for gas / HFO liquid fuel Based Power Plant

Information Required for Selection / Sizing/ Design of Power Plant
A SITE CONDITIONS
1) Altitude (m above Sea Level) :2) Maximum Ambient Temperature. ( C) :- 45 Degree Cent
3) Relative Humidity at Maximum Ambient ( % ) :4) Wet Bulb Temperature of the Area ( C) :5) Environment (Dusty / Clean) :- Clean
6) Presence of any Hazardous or Chemically :-Active Gases In Surrounding Air
7) Soil Condition at site (normal, marshy :- Normal black cotton etc.)
8) Soil bearing capacity :(< 15 tons/m2 or > 15 tons/m2)
9) Water table at site :-

B POWER REQUIREMENT ( As discussed personally present conditions given )

1) Maximum Demand (kVA) :-Max Demand reached in Last 4 Years - KVA
2) Minimum continuous process loads (kVA / kW) :3) Grid Voltage and Frequency :- 22 KV ( +/- 10 % ) Variation Percentage :- 50 Hz ( +/4% )
4) Whether Independent Auxiliary Power Supply?:- Yes ( 415 V) available
5) Proposed Power Plant capacity (MW) :- Option 1 - for 50 % Load; Option 2 - for 100 %
Load

C STEAM REQUIREMENT (IF ANY) If system can provide the steam it can be used
for preheating in our existing system.
At present we are using thermal oil based heating system

1) For process Steam (Quantity T/hr., :-pressure)

2) For air-conditioning / chillers etc. :-(quantity T/hr., pressure)
3) For fuel heating only :- For Fuel Heating
4) Existing Boiler(s) details :-

D FUEL
1) Type of fuel to be used :- HFO/ HPS / LSHS / FO / LDO / HSD / NG / BIOGAS
(Please provide specifications of fuel, in case of Gas Annexure IV shall be filled also)
2) Approximate price of fuel at site (Rs. / kL) :- Rs. 18000 per KL
3) Design Viscosity of Fuel handling System :-(380 or 500 cST at 50 C)
4) Fuel Handling and Storage Facility at site :- Tank of 65 KL capacity (If any for existing
Generating Sets)
INFORMATION REQUIRED TO DETERMINE OPERATING PHILOSOPHY
A POWER PLANT OPERATION :- Continuous (Continuous / Base Load / Standby /
Emergency / Peaking)
B PARALLEL OPERATION
1) With grid ( Yes / No ) :- Yes
2) Between proposed DG Sets (Yes / No ) :- Yes
3) With existing DG / TG Sets (Yes / No) :- No
Details of existing DG /TG sets (if parallel operations required.)
i) Supplier / Model / Name plate details :- We have Old 180 KVA DG set which are used at
present for Emergency Lighting etc incase of Power
shutdown / Breakdown
ii) Rating (kVA / kW) :- 180 KVA * 2 Nos
iii) Make / Model / Type of Governor :- Kirloskar
iv) Type of Excitation / AVR :-

v) Synchronization Facility :-

C SPECIAL REQUIREMENTS
1) Motor Starting Duty (If any) :- We have rolling mills. The (If yes, please provide details
wherever possible) maximum size of the motor is 750
HP DC having a full load current of 1006 Amp. When it starts from standstill it takes @ 1600
Amp + current.
2) Furnace application :- We have 3 No. Foil
Annealing Furnace. 1350 KW
3) Non-linear Thyristor Loads, if any :- Thyristor drives - Yes
4) Any other non-standard loads, if any :5) Voltage requirement (3.3 / 6.6 / 11 kV) :- 3.3 KV ( my existing feeder is 22 KV incoming
and Step down to 3.3 KV )
6) Water Availability :-(Sufficient - Cooling Towers, Scarce - Radiators)
If Yes in case of C1, C2 and / or C3 above Annexures - I. II and III (Page 5 of 8, 6 of 8 & 7
of 8) shall be filled also. In case of Non-linear loads please provide harmonics analysis
report also.
INFORMATION ABOUT THE CLIENT (PURCHASER / OWNER COMPANY)
1) Contact Person & Designation :Office Address / Telephone / Fax # -- Electrical Industries Ltd
2) Name / address / Tel. of Consultant (if any) :- NA
3) Annual Turnover of the Company :-Plant @ 168 Cr
4) Main Product and installed capacity :-Aluminum. foil & Packaging Products
5) Location of the Site :- Kalwa - Thane
6) Availability for proposed Power plant at site :7) Contact Person at Site :- As Above Address / Telephone / Fax #
8) Whether power requirement is for :- Existing Plant existing plant /expansion project /
new project

9) Duty structure :-(EPCG / EOU / Project Import / IPP)

10) Project Implementation Schedule :- FY 07-08 (Power Out - month / year)
11) Mode of Financing the Project :12) Type of Offer Required :- Budget + Firm (Feasibility Study / Indicative / Budget / Firm)
13) Cost of existing Power
(a) From Grid including Maximum. Demand Charges :- @ Rs. 4.4 per Unit
(b) Generated from other source :(DG / TG etc.)
Additional Information :Max Demand Charges Rs. 350 per KVA
Rate Rs. 2.85 per Unit
Other Charges Rs. 1.0 Per Unit
Avg. Unit Charge Rs. 4.4 per Unit
Avg. Consumption 1250000 units per month

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G.Swaminathan

DG Set rating at various power factor

Commentator

11/03/2007 1:02 PM

Join Date: May 2007

Location: Tamilnadu
Posts: 56

If the Diesel Generator is designed at

0.80 power factor for500kVA( 3phase,
415volts, 50Hz) capacity the full load
current will be 696 amps.But if we load
that DG set at 0.90 power factor the full
load current mentioned as 618
amps.This calculation arrived after
converting to 0.80 power factor since
generator designed for that PF.What is
the reason for this reduction of load
current as against Alternator, which is
over loaded only at lesser power
factor.Please indicate the reason in
detail.
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"official" good answers and, if you agree with them, rate them!
#4 "Re: DG Set rating at various power factor" by Anonymous
Poster on 11/04/2007 10:48 PM (score 1)
#5 "Re: DG Set rating at various power factor" by PetroPower on
11/05/2007 11:03 AM (score 1)
CoronaCameraMan
Power-User

#1
Re: DG Set rating at various power
factor
11/03/2007 11:42 PM

Join Date: Sep 2007

Location: Sheboygan,
WI USA
Posts: 370
Good Answers: 13

The generator minimum amperage will

be at Unity Power Factor with the
generator connected to a load larger
then generator kVA or synchronized to
the grid, as the voltage regulator is
adjusted the power factor is adjusted
leading or lagging, the generator
terminal voltage is fixed by the grid and
the generator amperage changes with
the change in voltage regulator setting.
Caution must be used when adjusting
the generator voltage regulator to make
sure you do not exceed rated power
factor because the generator can slip

poles causing mechanical damage.

You may find additional topics
answering this question.
__________________
"I believe we are masters of our lives we hold all the cards and it is up to us to
use them right." Vesna Vulova - survived
33,000ft fall
Register to Reply
ramvinod
Guru

#2
Re: DG Set rating at various power
factor
11/03/2007 11:56 PM

For the Diesel sets, the Prime mover

namely the diesel Engine has got
Join Date: Jun 2007
restricted power.In a 500 kVA set, the
Location: chennai,India engine can deliver only 400 kW
power.May be it can take 10 %
Posts: 533
overload.
Good Answers: 14

The alternator is rated for 500 kVA,0.8

pf.This can give an output of 400kw.
Supposing the alternator has to deliver
full load current of 696 Amps at pf of
0.9, the power required by the
Alternator from the engine would be
equal to 1.732X 415X696X0.9/1000,
(assuming efficiency 100%) which is
equal to 450 kW.Since the engine is
rated for 400kW, it cannot deliver
450kW
Therefore, DG set cannot be loaded

beyond rated current at rated power

factor also pf cannot be improved to
unity and at the same load the
alternator to rated current.
For any more clarifications you can
contact cbr@cuppu.com
__________________
Ramesh,Freelance
Electrical/automation Consultant
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Anonymous Poster
#4
In reply to #2
Re: DG Set rating at various power
factor
11/04/2007 10:48 PM
Thank you for your good feed back
Register to Reply Score 1 for Good
Answer
Go to Next "Almost" Good Answer
CEKM
Commentator

#3
Re: DG Set rating at various power
factor
11/04/2007 6:29 PM

G,
Power factor has always been a baffling
subject, I can remember in school
Location: Work Hawaii, sorting out the various formulas
Home Connecticut
calculating the current, KVA, and power.
I have sailed as an Instructor on a
Posts: 67
Maritime College Cadet training ship,
Good Answers: 4
instructing Diesel Engine, Refrigeration
and Air Conditioning, and Electricity. I
have attempted to simplify power factor
to explaining it as the ratio of the power
supplied by the source to a load, (True
Power), and the amount of power that
is reflected back to the source from the
load (Reactive power). The ammeter will
measure the sum of both currents, the
current flowing from the source to the
(Reactive) load, and the current flowing
back to the source from the load, thus
the KVA (Apparent Power) will be
greater than the true power (KW).
Join Date: Nov 2007

Citing the example you presented an

alternator operating at .8 power factor
is receiving 20% of the power it
produced and sent to the load reflected
back to the alternator and there
dissipated as heat.
Inductive loads reflect the power back
to the source with the current lagging
behind the voltage, Capacitive loads
reflect the power back to the source
with the current leading the voltage.
The power factor can be also expressed
as an angle, which is a vector of the true
power and the apparent power.
A purely restive load, as a incandescent
lamp or a heater will not reflect any
power back to the source, and therefore

the power factor is 1, or unity, all the

power delivered to the load from the
source is adsorbed by the load.. A
network system is likely to have both
capacitive and inductive loads on the
system, and if the inductive current is
equal to the capacitive current the
system will appear to the source as a
purely resistive load, and the power
factor of the network will be unity.
The same phenomenon occurs in radio
frequency circuits, only it is called
standing wave ratio. In radio an antenna
(Load) must be tuned to resonance so as
not reflect any power back to the
transmitter (Source). In radio the
phenomenon is explained as a pulse of
energy travels from the feed point of
the antenna to the end of the antenna
at the speed of light, and is reflected
back to the feed point. if the antenna is
too short the reflected energy arrives at
the feed point before the next voltage
pulse arrives at the feed point, and
some of the energy travels back to the
source ahead of the voltage pulse, the
reflected current leads the voltage, the
antenna is said to be capacitive. If the
antenna is too long the reflected pulse
arrives at the feed point after the next
pulse arrives from the source, and some
of the reflected energy travels back to
the source after the voltage pulse, the
current lags behind the voltage, the
antenna is said to be inductive. When
the antenna is just the right length, the
reflected pulse arrives at the feed point
at the same time as the next pulse from
the source, and no energy is reflected
back to the source, the antenna is

resonant, and appears to the source to

be purely resistive, the standing wave
ratio is 1:1, the power factor is unity.
Various means are employed on a
power grid and in radio frequency
circuits to correct for power factor,
capacitors are added to correct lagging
power factor, inductors to correct
leading power factor. Synchronous
motor excitation can be adjusted to
correct power factor, and Induction
generators will correct lagging power
factor.
Hope I didn't overload you with
information, I hope perhaps I explained
power factor without all the
mathematical mumbo jumbo.
I have worked in the Middle East
(Oman), and travelled in India, I have
great respect for Indian Engineers.
Regards CEKM
Register to Reply
PetroPower
Guru

#5
Re: DG Set rating at various power
factor
11/05/2007 11:03 AM
G,

Join Date: Jan 2007

Location: Sitting

You can search "Power Factor" to get

electrical and mathematical definitions
of PF. This answer is a practical
definition and how it changes your

directly behind my
keyboard in
Albuquerque - USA
Posts: 592
Good Answers: 19

machinery selection and how it will

affect your DG operation and life
expectancy of the engine and alternator
(generator).
Alternator (generator):
There are two types of loads that affect
your generator rating and life. First:
"Real Power" loads that convert energy
to heat, light or motion. We measure
these loads in 'watts'. Second: The other
load is "Reactive Power". This reactive
power is energy utilised to build and
maintain an electromagnetic field found
in capacitive loads (I can't think of too
many capacitive loads in a building . . .
maybe a large LCD panel ?) and
inductive loads (like an induction
motor). We measure these loads in
'volt-amps reactive' (VARs).
Watts do the real work (light - motion heat) and VARS just recirculate from the
load to the generator and back again as
a magnetic field. The VARs do no 'work',
but are necessary for the reactive loads
to operate. The VARs arrive to / from
the load in the form of extra amperes
(current flow) that are not doing any
'work' but DO cause the generator
windings to heat up more. So a 0.9 PF
load will have less amps than a 0.6 PF
load. Both loads might do the same
work measured in watts, but the type of
load that produces 0.6 PF will have
substantial recirculating magnetism
from the load to the generator and be
practically measured by noticing the
amps are much greater.
Both the watts and the reactive power

have current demand (amps) on the

generator. Watts tend to heat up the
stater windings primarily and the rotor
windings a bit less. VARs tend to heat up
the rotor windings primarily and the
stator winding a bit less.
Generator manufacturers have
standardised on an world wide power
factor average for a typical average load
to be 0.8 PF. This gives a base line for
manufacturing the average generator to
give the customer good life from the
stater winding and the rotor windings.
If you typically have very low power
factor loads such as consistently 0.6 PF,
then the generator maker will build
your rotor differently (add some cooling
tricks and some additional wire) and
they will add more stater winding wire
and different insulation to avoid the
damage due to heat. heat from Amps.
Amps from low power factor loads.
For high kilo-watt loads, this is real
'power' and take real engine power to
turn the generator during high kilowatt
loads. So they build the rotor shaft
stronger, bearings larger, bearing
cooling (oil or grease) differently, etc. So
there are electrical and mechanical
issues with watts and reactive power.
Lastly there is the temperature rise. This
will relate to how hot the winding get
during the rated load and the life of the
winding before the insulation breaks
down. There is an exponentially
relationship to the decrease in
insulation life when you exceed the
temperature rise. Temperature rise can

be exceeded if you specify a 0.8 PF

generator at 400 kW but you operate it
on loads with 0.6 PF. Amps = winding
heat.
Black start emergency standby
generators are typically rated for 130* C
rise over 40* C ambient (they only
operate a few hours a year in developed
countries). Continuous 24/7 full load
duty machines are rated for 80*C rise
over 50*C. Therefore a 400 kW, 500 kVA
unit rated at 80*C rise over 50* will
have MUCH more copper than a 400
kW, 500 kVA rated for 130*C rise over
40*C ambient.
Engine Power and life:
The engine will only 'see' the real power
watts load. Reactive loads recirculate
magnetism and current but this is not
'seen' as watts by the engine. So a 400
kW load at 1.0 PF uses the same engine
power (fuel) as a unit running at 400 kW
at 0.6 PF. The engine does not 'see' the
VARs. The generator will be MUCH
hotter on the 0.6 machine, but the
engine doesn't have any extra load.
So the engine people rate the engine
power demand ONLY on the watt rating.
A continuous duty 24/7 unit can
typically be overloaded 20% for one
hour in 24. A black start unit typically
cannot be overloaded at all, as it is
already rated very high to be
competitive (small engine running at
max power and small generator running
at max heat).
Hope this helps.

__________________
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Answer
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ramvinod
Guru

#6
In reply to #5
Re: DG Set rating at various power
factor
11/05/2007 1:17 PM

Join Date: Jun 2007

Nice and educative one.

Location: chennai,India ramesh

Posts: 533
Good Answers: 14

__________________
Ramesh,Freelance
Electrical/automation Consultant
Register to Reply

Anonymous Poster
#7
In reply to #6
Re: DG Set rating at various power
factor
05/01/2008 8:53 AM

Hi this is bala from Ethiopia,africa for

this case can we use some external
capacitors to make the power factor
from 0.6 lagging to 0.8 lagging
Register to Reply

ramvinod
Guru

#8
In reply to #7
Re: DG Set rating at various power
factor
05/01/2008 9:13 AM

The optimum pf is 0.8.therefore you can

connect capacitors to improve the pf to
Location: chennai,India 0.8 lag
Join Date: Jun 2007

Posts: 533
Good Answers: 14

__________________
Ramesh,Freelance
Electrical/automation Consultant
Register to Reply

Anonymous Poster
#9
Re: DG Set rating at various power
factor
08/14/2008 1:03 PM
Loading of DGSet is in KW. and KW is
fixed. If PF is increased then current will
be less and you can draw more current
from alternator. There will be no harm

on alternator but engine will be

effected. Can call me at 09971004445
SP Goel
Register to Reply Off Topic (Score 5)

Anonymous Poster
#10
Re: DG Set rating at various power
factor
02/12/2009 10:29 AM
dear sir,
normal DG designed at 0.8 PF if i am to
add capacitor up to 0.9 to 0.99.
what happen DG set any issue the DG
please replay
vijay_ppppl@yahoo.com
Register to Reply
Anonymous Poster
#11
Re: DG Set rating at various power
factor
01/08/2010 12:27 AM
sir
D G set power factor 0.8 standerd when
D g trai 0.75 pf 100 Amp ups conect 413

.412.413 Voltage 51 hz 90 Kw 1525 Rpm

what is Improve Pf 0.8
Register to Reply

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#4 "Re: DG Set rating at various power factor" by Anonymous
Poster on 11/04/2007 10:48 PM (score 1)
#5 "Re: DG Set rating at various power factor" by PetroPower on
11/05/2007 11:03 AM (score 1)
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