How not to select the wrong generator

set (genset) for your application

By Edvard July, 31st 2019

Home / Technical Articles / How not to select the wrong generator set (genset) for
your application

Generator Set Sizing and Ratings

Generator set is maybe the most expensive part you can find in a substation.
Therefore, many factors must be considered when determining the proper size or
electrical rating of an electrical power generator set. If wrong size or rate is selected
and delivered on site, the only thing you can do is to sit and cry.
How not to select the wrong generator set (genset) for your application (photo credit:
beyond the prism photography via Flickr)

The engine or prime mover is sized to provide the actual or real power in kW, as well
as speed (frequency) control through the use of an engine governor.

The generator is sized to supply the kVA needed at startup and during normal
running operation. It also provides voltage control through the use of a brushless
exciter and voltage regulator. Together the engine and generator provide the energy
necessary to supply electrical loads in many different applications encountered in
today’s society.

The generator set must be able to supply the starting and running electrical load. It
must be able to pick up and start all motor loads and low power factor loads, and
recover without excessive voltage dip or extended recovery time.

Nonlinear loads like variable frequency drives, uninterruptible power supply (UPS)
systems and switching power supplies also require attention because the SCR
switching causes voltage and current waveform distortion and harmonics. The
harmonics generate additional heat in the generator windings, and the generator may
need to be upsized to accommodate this.

The type of fuel (diesel, natural gas, propane, etc.) used is important as it is a factor in
determining generator set response to transient overloads.

It is also necessary to determine the load factor or average power consumption of the
generator set. This is typically defined as the load (kW) x time (hrs. while under
that particular load) / total running time. When this load factor or average power is
taken into consideration with peak demand requirements and the other operating
parameters mentioned above, the overall electrical rating of the genset can be
determined.

Other items to consider include the unique installation, ambient, and site requirements
of the project. These will help to determine the physical
configuration of the overall system.

Typical rating definitions for diesel gensets are: standby, prime plus 10, continuous
and load management (paralleled with or isolated from utility).

Any diesel genset can have several electrical ratings depending on the number oolkmf
hours of operation per year and the ratio of electrical load/genset rating when in
operation.

The same diesel genset can have a standby rating of 2000 kW at 0.8 power factor
(pf) and a continuous rating of 1825 kW at 0.8 pf. The lower continuous rating is
due to the additional hours of operation and higher load that the continuous genset
must carry. These additional requirements put more stress on the engine and generator
and therefore the rating is decreased to maintain longevity of the equipment.

Different generator set manufacturers use basically the same diesel genset electrical
rating definitions. These are based on International Diesel Fuel Stop Power standards
from organizations like ISO, DIN and others.

<="" ins="" data-adsbygoogle-status="done" data-overlap-observer-io="true">

Standby diesel genset rating

Typically defined as supplying varying electrical loads for the duration of a power
outage with the load normally connected to utility, genset operating <100 hours per
year and no overload capability.

Prime plus 10 rating

Typically defined as supplying varying electrical loads for the duration of a power
outage with the load normally connected to utility, genset operating <500 hours per
year and overload capability of 10% above its rating for 1 hour out of 12.

Continuous rating

Typically defined as supplying unvarying electrical loads (i.e., base loaded) for an
unlimited time.

Load management ratings

Apply to gensets in parallel operation with the utility or isolated/islanded from utility
and these ratings vary in usability from <200 hours per year to unlimited usage.

It’s highly advisable to refer to generator set manufacturers for further

definitions on load management ratings, load factor or average power
consumption, peak demand and how these ratings are typically applied.

Even though there is some standardization of these ratings across the manufacturers,
there also exists some uniqueness with regard to how each manufacturer applies their
generator sets.

Electrical rating definitions for natural gas powered gensets are typically defined as
standby or continuous with definitions similar to those mentioned above for diesels.

Natural gas gensets recover more slowly than diesel gensets when subjected to
block loads. Diesel engines have a much more direct path from the engine governor
and fuel delivery system to the combustion chamber, resulting in a very responsive
engine-generator.

A natural gas engine is challenged with air-fuel flow dynamics and a much more
indirect path from the engine governor (throttle actuator) and fuel delivery system
(natural gas pressure regulator, fuel valve and actuator, carburetor mixer, aftercooler,
intake manifold) to the combustion chamber. This results in a less responsive engine-
generator.

Diesel gensets recover about twice as fast as natural gas gensets!

<="" ins="" data-adsbygoogle-status="done" data-overlap-observer-io="true">

Genset software

Considering factors such as site conditions, load characteristics and required

performance, SpecSizer (Caterpillar’s genset software) provides accurate and
timely technical data, robust load models and optimized algorithms to assist in
specifying a properly sized generator set to best meet your power needs.

Several features set SpecSizer apart as a revolutionary tool in generator set sizing,
including its ability to evaluate load types such as air conditioners, elevators,
ultraviolet lights, single-phase NEMA and single-phase IEC motors.

Home / Technical Articles / How not to select the wrong generator set (genset) for your
application

Generator Set Sizing and Ratings

Generator set is maybe the most expensive part you can find in a substation.
Therefore, many factors must be considered when determining the proper size or
electrical rating of an electrical power generator set. If wrong size or rate is selected
and delivered on site, the only thing you can do is to sit and cry.
How not to select the wrong generator set (genset) for your application (photo credit:
beyond the prism photography via Flickr)

The engine or prime mover is sized to provide the actual or real power in kW, as well
as speed (frequency) control through the use of an engine governor.

The generator is sized to supply the kVA needed at startup and during normal
running operation. It also provides voltage control through the use of a brushless
exciter and voltage regulator. Together the engine and generator provide the energy
necessary to supply electrical loads in many different applications encountered in
today’s society.

The generator set must be able to supply the starting and running electrical load. It
must be able to pick up and start all motor loads and low power factor loads, and
recover without excessive voltage dip or extended recovery time.

Nonlinear loads like variable frequency drives, uninterruptible power supply (UPS) systems
and switching power supplies also require attention because the SCR switching causes
voltage and current waveform distortion and harmonics. The harmonics generate additional
heat in the generator windings, and the generator may need to be upsized to
accommodate this.

The type of fuel (diesel, natural gas, propane, etc.) used is important as it is a factor in
determining generator set response to transient overloads.

It is also necessary to determine the load factor or average power consumption of the
generator set. This is typically defined as the load (kW) x time (hrs. while under
that particular load) / total running time. When this load factor or average power is
taken into consideration with peak demand requirements and the other operating
parameters mentioned above, the overall electrical rating of the genset can be
determined.

Other items to consider include the unique installation, ambient, and site requirements
of the project. These will help to determine the physical
configuration of the overall system.

Typical rating definitions for diesel gensets are: standby, prime plus 10, continuous
and load management (paralleled with or isolated from utility).

Any diesel genset can have several electrical ratings depending on the number of
hours of operation per year and the ratio of electrical load/genset rating when in
operation.

The same diesel genset can have a standby rating of 2000 kW at 0.8 power factor (pf) and a
continuous rating of 1825 kW at 0.8 pf. The lower continuous rating is due to the additional
hours of operation and higher load that the continuous genset must carry. These additional
requirements put more stress on the engine and generator and therefore the rating is
decreased to maintain longevity of the equipment.

Different generator set manufacturers use basically the same diesel genset electrical
rating definitions. These are based on International Diesel Fuel Stop Power standards
from organizations like ISO, DIN and others.

<="" ins="" data-adsbygoogle-status="done" data-overlap-observer-io="true">

Standby diesel genset rating

Typically defined as supplying varying electrical loads for the duration of a power
outage with the load normally connected to utility, genset operating <100 hours per
year and no overload capability.

Prime plus 10 rating

Typically defined as supplying varying electrical loads for the duration of a power
outage with the load normally connected to utility, genset operating <500 hours per
year and overload capability of 10% above its rating for 1 hour out of 12.

Continuous rating

Typically defined as supplying unvarying electrical loads (i.e., base loaded) for an
unlimited time.

Load management ratings

Apply to gensets in parallel operation with the utility or isolated/islanded from utility
and these ratings vary in usability from <200 hours per year to unlimited usage.

It’s highly advisable to refer to generator set manufacturers for further

definitions on load management ratings, load factor or average power
consumption, peak demand and how these ratings are typically applied.

Even though there is some standardization of these ratings across the manufacturers,
there also exists some uniqueness with regard to how each manufacturer applies their
generator sets.

Electrical rating definitions for natural gas powered gensets are typically defined as
standby or continuous with definitions similar to those mentioned above for diesels.

Natural gas gensets recover more slowly than diesel gensets when subjected to block
loads. Diesel engines have a much more direct path from the engine governor and fuel
delivery system to the combustion chamber, resulting in a very responsive engine-generator.

A natural gas engine is challenged with air-fuel flow dynamics and a much more
indirect path from the engine governor (throttle actuator) and fuel delivery system
(natural gas pressure regulator, fuel valve and actuator, carburetor mixer, aftercooler,
intake manifold) to the combustion chamber. This results in a less responsive engine-
generator.

Diesel gensets recover about twice as fast as natural gas gensets!

<="" ins="" data-adsbygoogle-status="done" data-overlap-observer-io="true">

Genset software

Considering factors such as site conditions, load characteristics and required

performance, SpecSizer (Caterpillar’s genset software) provides accurate and
timely technical data, robust load models and optimized algorithms to assist in
specifying a properly sized generator set to best meet your power needs.

Several features set SpecSizer apart as a revolutionary tool in generator set sizing,
including its ability to evaluate load types such as air conditioners, elevators,
ultraviolet lights, single-phase NEMA and single-phase IEC motors.

For the actual calculations involved for sizing a genset, there are readily accessible
computer software programs that are available on the genset manufacturer’s websites
or from the manufacturer’s dealers or distributors. These programs are used to quickly
and accurately size generator sets for their application.

The programs take into consideration the many different parameters discussed
above, including:

 The size and type of the electrical loads (resistive, inductive, SCR, etc.),
 Reduced voltage soft starting devices (RVSS),
 Motor types,
 Voltage,
 Fuel type,
 Site conditions,
 Ambient conditions and
 Other variables.

The software will optimize the starting sequences of the motors for the least amount of
voltage dip and determine the starting kVA needed from the genset. It also provides
transient response data, including voltage dip magnitude and recovery duration. If the
transient response is unacceptable, then design changes can be considered, including
oversizing the generator to handle the additional kvar load, adding RVSS devices
to reduce the inrush current, improving system power factor and other methods.

The computer software programs are quite flexible in that they allow changes to the
many different variables and parameters to achieve an optimum design. The software
calculates how to minimize voltage dips and can recommend using paralleled gensets
vs. a single genset.

Genset Sizing Guidelines

Some conservative rules of thumb for genset sizing include:

 1. Oversize genset 20–25% for reserve capacity and for across the line motor starting.
2. Oversize gensets for unbalanced loading or low power factor running loads.
3. Use 1/2 hp per kW for motor loads.
4. For variable frequency drives, oversize the genset by at least 40% for sixpulse
technology drives.
5. For UPS systems, oversize the genset by 40% for 6 pulse and 15% for 6 pulse with
input filters or 12 pulse.
6. Always start the largest motor first when stepping loads.

For basic sizing of a generator system, the following example could be used:

Step 1 – Calculate Running Amperes

 Motor loads:
o 200 hp motor: 156 A
o 100 hp motor: 78 A
o 60 hp motor: 48 A
 Lighting load: 68 A
 Miscellaneous‫ متنوع‬loads: 95 A
 Running amperes: 445 A

Step 2 – Calculating Starting Amperes Using 1 25 Multiplier

 Motor loads:
o 200 hp motor: 195 A
o 100 hp motor: 98 A
o 60 hp motor: 60 A
 Lighting load: 68 A
 Miscellaneous loads: 95 A
 Starting amperes: 516 A

Step 3 – Selecting kVA of Generator

 Running kVA = (445 A × 480 V × 1.732) / 1000 = 370 kVA

 Starting kVA = (516 A × 480 V × 1.732) / 1000 = 428 kVA

Solution

Generator must have a minimum starting capability of 428 kVA and minimum
running capability of 370 kVA.
Figure 1 – Typical genset installation

Generator Set Installation and Site Considerations

There are many different installation parameters and site conditions that must be
considered to have a successful generator set installation. The following is a partial
list of areas to consider when conducting this design.

Some of these installation parameters include:

1. Foundation type (crushed rock, concrete, dirt, wood, separate concrete inertia pad,
etc.)
2. Foundation to genset vibration dampening (spring type, cork and rubber, etc.)
3. Noise attenuation (radiator fan mechanical noise, exhaust noise, air intake noise)
4. Combustion and cooling air requirements
5. Exhaust backpressure requirements
6. Emissions permitting
7. Delivery and rigging requirements
8. Genset derating due to high altitudes or excessive ambient temperatures
9. Hazardous waste considerations for fuel, antifreeze, engine oil
10. Meeting local building and electrical codes
 11. Genset exposure (coastal conditions, dust, chemicals, etc.)
12. Properly sized starting systems (compressed air, batteries and charger)
13. Allowing adequate space for installation of the genset and for maintenance (i.e., air
filter removal, oil changing, general genset inspection, etc…)
14. Flex connections on all systems that are attached to the genset and a rigid structure
(fuel piping, foundation vibration isolators, exhaust, air intake, control wiring, power
cables, radiator flanges/duct work, etc.)
15. Diesel fuel day tank systems (pumps, return piping)
16. Fuel storage tank (double walled, fire codes) and other parameters

Please see the generator set manufacturer’s application and installation guidelines for
proper application and operation of their equipment.