LEBE5294 - Electric Power Applications - Engine & Generator Sizing

APPLICATION AND INSTALLATION GUIDE
ELECTRIC POWER
APPLICATIONS, ENGINE &
GENERATOR SIZING
Contents
Generator Set Rating Considerations ................................... 2

Rating Definitions ......................................................... 2
Engine/Generator Set Load Factor ............................... 2
Emergency Standby Power ........................................ 3
Standby Power ......................................................... 3
Prime Power............................................................. 3
Continuous Power..................................................... 3
The International Standards Organization (ISO) ............. 3
Continuous Operating Power (COP)............................. 3
Prime Running Power (PRP)........................................ 3
Limited-Time Running Power (LTP).............................. 4
Load Management ........................................................ 4
Isolated from the Utility Under 500 Hours per Year ....... 4
Isolated from the Utility Over 500 Hours per Year......... 4
Paralleled with the Utility Under 500 Hours per Year ..... 5
Paralleled with the Utility Over 500 Hours per Year....... 5
Standards .................................................................... 5
Generator Rating Capability ........................................ 5
Generator Mapping Limits .......................................... 7
Site Conditions Impact on Genset Ratings........................ 7
Altitude ................................................................... 8
Heat........................................................................ 8
Corrosive Atmospheres.............................................. 8
Humidity .................................................................. 8
Dust........................................................................ 9
Transient Response....................................................... 9
Sizing Criterion ......................................................... 9
Motor Starting .........................................................11
Block Load ..............................................................12
Transient Response Standards.......................................12
Engine Considerations ..............................................13
Engine Configuration ................................................17
Air System..............................................................17
Gas Engines ............................................................17
Block Load and Transient Capability ...........................17
System Interaction ...................................................18
Voltage Regulators...................................................19
Digital Voltage Regulator ..........................................20
Customer Requirements....................................................21
Power Demand ............................................................21
On Site Power Requirement ......................................21
Load Management ...................................................21
Loads Profiles ..........................................................21
Estimating Load Data ...............................................23
Categorizing Loads...................................................23
VA/FT2 Load Estimating ............................................24
Load Steps..................................................................25
Prioritization ............................................................25
Load Shedding.........................................................26
Intermittent Loads....................................................26
Additional Load Categories........................................26
Load Management Strategies ....................................26
Peak Shaving...........................................................26
Base Loading...........................................................27
Zero Import/Zero Export............................................27
Peak Sharing ...........................................................28
Co-generation..........................................................28
Load Duration Curves ...............................................28
Estimating Guidelines ...............................................29
Load Growth ...........................................................29
Demand Factor ............................................................30
Diversity Factor ...........................................................31
Demand Factor and Diversity Factor in Sizing ..................31
Frequency Dips........................................................32
Block Load & Standards............................................32
Starting Requirements ..................................................32
Load Acceptance .....................................................33
Ten-Second Start .....................................................33
Health Care Facilities & NFPA 99 ...............................34
Fuel Selection..........................................................34
Performance................................................................34
Emissions................................................................34
Correction Factors ...................................................36
Nominal vs. Not to Exceed ........................................36
Heat Balance ...........................................................37
Co-generation Usage ................................................37
Load Analysis..................................................................38
Lighting Loads .............................................................39
Linear Lighting Loads................................................39
Lighting ..................................................................39
Incandescent Lighting...............................................39
Tungsten Lamp Inrush ..............................................40
Non-Linear Lighting Loads .........................................40
Fluorescent Lamps ...................................................40
Gas Discharge Lamps ...............................................40
Motor Loads................................................................41
Induction Motors .....................................................42
Wound Rotor (Slip Ring) ...........................................43
Slip Definition..........................................................43
Synchronous Motors ................................................44
DC Motors ..............................................................45
Single-phase Motors.................................................45
Three-Phase Motors .................................................46
Motor Performance ......................................................46
Design Class ...........................................................46
Motor Starting .........................................................48
Starting Power Factor...............................................50
Motor Starting Load .................................................51
Motor Torque ..........................................................52
Motor Voltage .........................................................56
Motor Starting Techniques ............................................57
Full Voltage Starting.................................................57
Soft Starting — Cushioning Motor Starting Under Load 60
Reduced Voltage Starting..........................................60
Reduced Starting Methods ........................................62
Intermittent Starting .................................................68
Motor Starting Troubleshooting Techniques ................68
Miscellaneous Loads ....................................................69
Adjustable (Variable) Speed Drives .............................69
Silicon Controlled Rectifier (SCR) Systems ..................70
Welding Loads .........................................................71
Uninterruptible Power Supply (UPS) ...........................71
Regenerative Power .................................................77
Transformers...........................................................78
Critical Loads ..........................................................80
Helpful Load Application Tips ....................................80
Single-Phase Loads ..................................................84
Load Balancing ........................................................84
One-line Diagrams....................................................86
Genset Selection Considerations........................................91
Load Types .................................................................91
Linear Loads............................................................91
Non-Linear Loads .....................................................92
Harmonic Content........................................................93
Generator Considerations..............................................95
Generator Heating....................................................95
Generator Reactance Impact .....................................95
Waveform Distortion ................................................96
Generator AVR and Excitation ...................................98
Determining Distortion ..............................................98
Generator Pitch........................................................99
2/3 Pitch.................................................................99
Non-Linear Loads and 2/3 Pitch .................................99
Paralleling and 2/3 Pitch .........................................100
Applications Requiring 2/3 Pitch ..............................100
Other Generator Set Selection Considerations ...........100
Voltage Range/Number of Leads ..............................100
Genset Voltage Selection ........................................102
Multi-Engine Installations ............................................102
Paralleling .............................................................103
Droop and Governors .............................................106
Regulator Compensation .........................................107
Load Control .........................................................108
Load Order ............................................................108
Unit Shutdown ......................................................108
Foreword
This section of the Application and Installation Guide generally describes
Electric Power Application, Engine and Generator Selection for Caterpillar®
engines. Additional engine systems, components and dynamics are
addressed in other sections of this Application and Installation Guide.
Engine-specific information and data are available from a variety of
sources. Refer to the Introduction section of this guide for additional
references.
Systems and components described in this guide may not be available or
applicable for every engine.
Information contained in this publication may be considered confidential.

Discretion is recommended when distributing. Materials and specifications
are subject to change without notice.
CAT, CATERPILLAR, their respective logos and “Caterpillar Yellow”, as well

as corporate and product identity used herein, are trademarks of Caterpillar
and may not be used without permission.
©2005 Caterpillar®
All rights reserved.
Application and Installation Guide EP Applications, Engine & Generator Sizing
Electric Power Applications, Engine & Generator

Sizing
On-site engine/generator sets (gensets) are used in a variety of
applications. They are becoming more popular for load management
applications since the deregulation and privatization of the utility industry.
Some gensets are used strictly as “back-up” for emergencies and some as
the only power source.
Although computer programs can be used to assist in proper generator
sizing, an understanding of the formulas, calculations and non-numerical
factors is beneficial to determine proper generator sizing.
The following subjects must be considered and are specifically addressed in
this section.
• Engine Ratings
• Customer Applications
• Load Analysis
• Genset Selection Criteria
• Multi-Engine Installations
SECTION CONTENTS
Generator Set Rating • Demand & Diversity Factors

Considerations..................... 2 in Sizing
• Rating Definitions • Starting Requirements
• Load Management • Performance
• Standards Load Analysis.....................38
• Site Conditions Impact on • Lighting Loads
Genset Ratings • Motor Loads
• Transient Response • Motor Performance
• Transient Response • Motor Starting Techniques
Standards
• Miscellaneous Loads
Customer Requirements.......21
Genset Selection
• Power Demand
Considerations ...................91
• Load Steps • Load Types
• Demand Factor • Harmonic Content
• Diversity Factor • Generator Considerations
• Multi-Engine Installations
All rights reserved. Page 1
EP Applications, Engine & Generator Sizing Application and Installation Guide
Generator Set Rating Considerations

power can be determined by
Rating Definitions
performing a load analysis on the
A generator set (genset) consists
facility. This involves making a
of an engine and a generator.
survey of the power requirements
However, it is best to consider the
over a period of time.
engine and generator as a system.
Individually, each has unique ekW = pf x kVA
characteristics; but together these ekW
bkW = + Fan Demand
qualities have a significant impact on eff
the performance and sizing of the kVA = kVA output of generator
genset system. pf = power factor of connected load
Capabilities of both engine and ekW = electrical power (electrical kW)
generator are considered individually
bkW = engine power (brake kW)
and collectively when selecting
generator sets. Engines produce eff = generator efficiency
brake horsepower (or kilowatts) When kW is qualified as neither
while controlling speed or frequency. electrical (ekW) nor brake (bkW), it
Generators influence engine is important to clarify between the
behavior, but are primarily two when performing calculations or
responsible for changing engine product comparisons.
power into kilovolt-amperes (kVA)
Engine/Generator Set Load Factor
and electrical kilowatts (kW). They
Load factor of a generator set is
also must satisfy high “magnetizing
used as one criterion for rating a
current” draws (kVAR), or transient
genset. It is calculated by finding the
conditions from electrical equipment.
product of various loads:
Normally, a generator set is
Load Factor = % of time x % of load
furnished with a generator which
matches the engine output
capability. Engines are sized time at specific load
% of time =
according to the actual power in kW total operating time
required to meet the needs of the
facility. The generator, on the other specific load
hand, must be capable of handling % of load =
rated load
the maximum apparent power which
is measured in kVA. The actual
Extended idling time and the time
power can be identified in several
when the generator set is not
ways. It can be calculated by adding
operating does not enter into the
the nameplate ratings of the
calculation for load factor.
equipment to be powered by the
generator. If this is done, the For example, assume a facility has
efficiencies of the equipment must a genset rated at 550 kW and runs it
also be considered. The actual two hours a week. During those two
Page 2 All rights reserved.
hours, it runs at 400 kW for 1.5 power over each 24 hour period.
hours. Find the load factor. 10% overload limited to 1 in 12
The formulas reveal the following: hours but not to exceed 25 hours
per year. The 10% overload is
400 kW
% of load = = 0.73 available in accordance with ISO
550 kW
3046-1 (2002). Life to overhaul of
the engine is dependent on operation
90 min. as outlined in ISO8528 (2005) and
% of time = = 0.75
120 min. time spent during operation above
100% load may affect the life to
Load Factor = 0.73 x 0.75 = 54.75% overhaul.
Continuous Power
This load factor would indicate Unlimited hours of usage. Load
that the genset could be used as a factor 100% of the published
standby rated genset because it Continuous Power. Generally, as ISO
meets the load factor and other 8528 (2005) Continuous power.
criteria of standby. Note: Operating above these rating
Power rating definitions for definitions will result in shorter life
Caterpillar generator sets are based and higher generator and engine
on typical load factor, hours of use costs per year.
per year, peak demand and The International Standards
application use. Caterpillar genset Organization (ISO)
ratings for emergency standby, ISO 8528-1 (2005) defines three
standby, prime and continuous types of duty:
power are listed.
• Continuous Operating Power
Emergency Standby Power (COP)
Typical usage of 50 hours per year • Prime Running Power (PRP)
with a maximum of 200 hours per
year. Typical variable load factor of • Limited-Time running Power
70%. (LTP)
Standby Power Continuous Operating Power (COP)

Maximum usage 500 hours per Continuous operating power is the
year, up to300 hours of which may power a generator set can operate at
be continuous running with varying a continuous load for an unlimited
loads. No overload is available. number of hours under stated
Rating is equivalent to Prime +10%. ambient conditions. Maintenance
Load factor maximum is 70% of according to the manufacturer must
Standby rating. be followed to reach these
standards.
Prime Power
Unlimited hours of usage. Load Prime Running Power (PRP)
factor (70% maximum /80% if no Prime running power is the
extra cost) of the published Prime maximum power a generator set has
during a variable power sequence for Isolated from the Utility Under 500
an unlimited number of hours under Hours per Year
stated ambient conditions. Output available with varying load
Maintenance according to the for less than 6 hours per day*.
manufacturer must be followed to * Fuel Stop Power in accordance with ISO 3046/1,
AS2789, DIN6271 and BS5514.
reach these standards.
Typical Load Factor = 60% or Less
Limited-Time Running Power (LTP)
Limited-time running power is the Typical Hours per Year = Less than 500 hours
maximum power that a generator set Typical Peak Demand = 80% of rated ekW
delivers for up to 500 hours per year with 100% of rating
under stated ambient conditions. available for
Only 300 hours can be continuous duration of an
running. Maintenance according to emergency outage.
the manufacturer must be followed Typical Application = Interruptible utility
to reach these standards. rates, peak sharing.
Specifications are often stated in
ISO terms and standards. Table 1
Isolated from the Utility Over 500
shows ISO genset ratings and
Hours per Year
correlating Caterpillar genset ratings.
Output available without varying
load for over 500 hours per year and
Generator Set Ratings less than 6 hours per day**.
** Prime Power in accordance with ISO 8528.
ISO Caterpillar Overload Power in accordance with ISO 3046/1,
Emergency Standby AS2789, DIN6271 and BS5514.
ESP
Power Typical Load Factor = 60% to 70%
LTP Emergency Standby
Typical Hours per Year = More than 500
PRP Prime hours
COP Continuous Typical Peak Demand = 100% of prime plus
10% rating used
Table 1
occasionally.
Load Management Typical Application = Peak sharing or
Load management is the deliberate cogeneration.
control of loads on a genset and/or
utility to have the lowest possible
electrical costs. In addition,
Caterpillar has two broad rating
categories in terms of load
management:
• Isolated from a utility
• Paralleled with a utility
and the Society for Automotive

Paralleled with the Utility Under 500
Engineers (SAE) standards. Each
Hours per Year
organization uses different
Output available without varying
load for under 500 hours per year. techniques and tolerances for power
ratings and fuel consumption.
Typical Load Factor = 60% to 70%
ISO standard 3046-1 is specific to
Typical Hours per Year = Less than 500 hours engines and ISO 8528 is followed
Typical Peak Demand = 100% of prime for the generator set.
rating used ISO 8528 has 12 sections. The
occasionally. first section describes applications,
Typical Application = Peak sharing. ratings and performance. The
remaining sections are listed below,
by section number.
Paralleled with the Utility Over 500 2. Specifies characteristics of
Hours per Year engine.
Output available without varying 3. Alternating current generators
load for unlimited time***. 4. Control gear & switchgear
*** Continuous Power in accordance with ISO
8528, ISO 3046/1, AS2789, DIN6271 and BS5514.
specifications
5. Generating set specifications
Typical Load Factor = 70% to 100%
6. Specifies test methods
Typical Hours per Year = No limit 7. Technical declarations for
Typical Peak Demand = 100% of continuous specification and design
rating used 100% of 8. Low power generator sets
the time. 9. Requirements on
Typical Application = Base load, utility, measurement and evaluation
peak sharing, of mechanical vibration
cogeneration, 10. Standards for noise
parallel operation. 11. Dynamic, uninterrupted power
supply systems
12. Emergency power supply to
Depending on how the genset will safety services
be applied will determine the size
Generator Rating Capability
needed. For example, if for a given
Gensets are limited in their ratings
load, the genset will only be used as
by the conditions and applications of
standby for a critical load only, then
both the generator and engine.
a smaller kW genset can be used,
rather than one used for prime Generator ratings are typically
power. thermal limited. They are limited by
the amount of internal heat that is
Standards created and then the amount of heat
Caterpillar generator sets are in that is dissipated. A more precise
accordance with The International definition is the increase in winding
Standardization Organization (ISO) temperature above the ambient
temperature. In other words, some

heat is retained within the unit, Genset
Generator Temperature
raising the temperature of the unit. Package
Class Rise °C
The National Electrical Rating
Manufacturers Association (NEMA) F 80 Continuous
H —
generator ratings are based on the F 105 Prime
generators “temperature rise” limit. H 125 Prime
Outside the United States, the F 130 Standby
International Electrotechnical H 150 Standby
Commission (IEC) has limits on Table 2
temperature rise for generators;
these may be found in IEC 6034-22 For prime power, the F class has a
(1996) and IEC 6034-1 (2004). 105°C rise or total temperature limit
Temperature rise is the increase in of 155°C (40°C ambient
winding temperature above the temperature + 10°C hot-spot
ambient temperature. Ambient margin + 105°C temperature rise)
temperature is the temperature of or less.
the cooling air as it enters the The H class allows for a 125°C
ventilating openings of the machine. rise or total temperature limit of
This temperature rise occurs 175°C or less:
because of the flow of current in the 40°C + 10°C + 125°C
windings and internal losses that
occur in the machine during
For standby power, the F class has
operation.
a 130°C temperature rise limit or
The most common classes of 180°C total temperature:
generators are the “F” and “H”
40°C + 10°C + 130°C
class. For all classes, NEMA
assumes operation at 40°C ambient
or lower. The temperature rise limits The H class has a 150°C
also allow for a 10°C margin for temperature rise or 200°C total
hot-spots. A hot-spot is the spot in temperature limit:
stator windings with the highest 40°C + 10°C + 130°C
temperature.
Table 2 shows temperature rise for
F and H class generators at various Voltage plays a key role in
ratings. generator rating and must be
considered. In some cases,
generator voltage will not match the
preferred operating voltage. A
voltage regulator can provide voltage
adjustment capability, however,
when “dialing down” generator
voltage, the current will increase for
a given rating. This will increase

generator heat and may require
generator derating. An alternative to
generator derating is to use a larger
generator to maintain the standard
rating.
The standard set by NEMA allows
a generator to be adjusted up or
down by five percent (± 5%) as
installed. Caterpillar generators
typically have a minimum 10% dial
down capability; in some cases this
may result in a derate. Some
generators are specifically designed
as broad-range and may not require
derating. A check of the
manufacturer’s data is recommended
when using generators at “off-
design” voltage.
Generator Mapping Limits
Figure 1 is a reactive capability Figure 1
chart for a salient-pole generator. A
load point within this area defines Site Conditions Impact on
the: Genset Ratings
• Active Power An engine rating is primarily limited
• Reactive Power by structural and thermal limits.
These limits include maximum
• Apparent Power cylinder pressure during combustion,
• Current turbocharger speed, exhaust gas
• Power Factor temperature and in natural gas
engines, fuel type. Where an engine
• Excitation
operates relative to these limits will
The heavy dark line, with points determine the maximum altitude and
labeled m-n-p-s-q-u-t, indicates ambient temperature for a given
absolute limits that are tolerated in a rating. When an engine exceeds the
machine. Generators are rated within maximum altitude or ambient
these limits. (See the Generator temperature, the engine must be
Section for additional details.) derated.
The environment or site conditions
also impact an engine or generator
rating, thus impacting the rating of
the entire genset. Conditions which
may affect a rating include altitude,
temperature, corrosive atmospheres, The altitude/temperature derating

humidity, and dust. chart found in TMI can be used for
Altitude and temperature most proper derating information.
heavily influence engine ratings. The Corrosive Atmospheres
higher the altitude, the lower the air Salt and other corrosive elements
density. Clean dense air is needed can cause damage to the winding
for efficient combustion. Likewise, insulation which can lead to failure
an increase in temperature lowers air of the generator. Protection from
density. Therefore, a derate of the these elements includes additional
engine must occur in high altitude coatings of insulation on the
and/or high temperature conditions windings during the manufacturing
in order for the genset to meet process and epoxy compounds as a
performance expectations. final winding overcoat.
Altitude Humidity
Generators operating at altitudes Condensation resulting from
above 1000 M (3281 ft.) require humidity will present a problem for
temperature rise reduction of 1% for all generators unless they are fully
every 100 M (328 ft.) above base enclosed. Temperature rise of the
(1000 M or 3281 ft.). A derate chart machine and the circulation of
is available in TMI for generators and cooling air with sufficient load
each specific engine. Figure 2 shows operation will usually prevent
a sample engine TMI derate chart. condensation. Space heaters should
Heat be used to raise the temperature to
Where the temperature of the 5°C above the ambient temperature
ventilating air to the generator to prevent condensation in high
exceeds 40°C (104°F), derating of humidity areas.
the generator may be necessary.
Figure 2
dip depends on the amount of active

Dust
power (kW) and reactive power
Conductive or abrasive dust drawn
(kVAR) changes based upon the
in through the cooling fan can be
voltage regulator settings, the total
very harmful to the generator.
capacity and dynamic characteristics
Examples of abrasive dust are: cast
of the generator set and the
iron dust, carbon dust, sand,
electrical inertia of the other loads in
powdered graphite, coke dust, lime
the system. On removal of load, the
dust, wood fiber, and quarry dust.
engine speed increases momentarily
When these foreign particles blow
(generally referred to as overshoot),
through the generator, they act as
then returns to its steady-state
sandpaper scraping away the
condition. The time required for the
insulation. These abrasions can
generator set to return to its normal
cause an electrical short within the
steady-state speed is called recovery
generator. An accumulation of these
time. This is illustrated in Figure 3.
materials in the crevices of the
insulation system will act as an
insulator or as a moisture attractor.
Filters which fit over the unit’s
intake air openings or enclosure
ventilation openings can prevent
damage. When using filters, it is
important that they be regularly
changed so as not to impede
airflow. The use of a generator air
filter will cause the generator to be
derated due to higher temperature
Figure 3
rise resulting from reduced cooling
airflow. Differential pressure Sizing Criterion
switches may be available as an Three primary criteria need to be
option on many generator sets. provided to accurately size a
generator set:
Transient Response
Whenever a load is applied to or • The acceptable percent of
removed from a generator set, the voltage & frequency dip
engine speed rpm, voltage and • The acceptable duration of the
frequency are temporarily changed voltage & frequency dip
from its steady-state condition. This recovery time
temporary change is called transient • The percent of a load step and
response. When a significant load is type of load to be connected
applied, the engine speed
temporarily reduces (generally The larger the voltage dip a
referred to as frequency or voltage generator set can tolerate, the
dip) and then returns to its steady- smaller and perhaps more
state condition. The degree of this economical the generator set can be.
A 30% maximum voltage dip is a lighting is fluorescent rather than

typical limit for industrial motor incandescent.
control centers. Sensitive loads may Reciprocating compressors
be written in spec for much lower seriously affect lighting quality.
voltage dips. UPS, variable speed Torque pulsations vary motor
drives, and medical equipment are all current, causing sufficient voltage
examples of loads which need small fluctuation to flicker lights.
voltage dips. Unfortunately, this is a frequency to
The human eye is sensitive to which eyes are extremely sensitive.
slight lighting fluctuations. Even a A commonly accepted figure for
decrease of 1/2 volt on a 110 volt current variation limits for motor-
incandescent bulb is noticeable. A driven reciprocating compressors is
one volt dip, if repeated, becomes 66% of full rated motor current. This
objectionable. Figure 4 shows the limits horsepower rating of
range of observable and compressor motors to about 6% of
objectionable voltage dips, assuming generator kVA rating, which is in the
direct illumination and medium-sized limit of objectionable light flicker. For
bulbs. example, a 30 hp motor may be
If indirect lighting is used with no used on systems having not less
incandescent bulbs below 100 than 500 kVA of generator capacity
watts, these values may be in operation (30 is 6% of 500).
broadened. This is also true if all
Figure 4
Typical voltage dip limitations are A properly sized generator will

found in Table 3 for various support the high starting kVA (skVA)
facilities. required and sustain adequate
output voltage for the motor so it
can produce the needed torque to
Typical Voltage Dip Limitations
accelerate its load to rated speed.
Permissible
Facility Application
Voltage After the initial voltage dip, it is
Dip important that the generator restore
Hospital, hotel Lighting load, 2% voltage to at least 90% to develop
motel, large Power Infrequent
apartments, load, large
adequate torque to accelerate its
libraries, Flickering highly load to rated speed. Full voltage
schools, and objectionable.
stores.
starting causes the largest voltage
Movie Theaters Lighting load, 3% dip. For this reason, public utilities
(sound tone large Flickering Infrequent
requires objectionable.
will not always allow full voltage
constant starting of large motors. Details on
frequency. Neon
flashers erratic)
motor starting are later discussed in
Bars and Power load, 5% - 10% the “load analysis” section of this
resorts. large Some
flicker
Infrequent guide.
acceptable Transient response of a genset is a
Shops, Power load, 3% - 5%
factories, mills, large Some Frequent description of the maximum voltage
laundries. flicker and frequency change on application
acceptable
Mines, oil field, Power load, 25% - 30% of a load and the time to recover to
quarries, large Flicker Frequent nominal voltage and frequency
asphalt, plants. acceptable.
Greater voltage fluctuations permitted with emergency power systems.
conditions. Typically, the maximum
allowable voltage dip is 30%. The
Table 3
maximum frequency dip is about
25% but modern equipment is
Motor Starting
restricting this to tighter margins.
The genset’s ability to start large
motors without large frequency or It is not always necessary to have
voltage dips depends on the entire the quickest transient response
system. System factors include: possible; only the best response for
the application’s need. Gensets all
• Available engine power
perform differently by the design of
• Capacity of the generator the engine, governing, and voltage
• Energy stored in the rotating regulation systems. Transient
inertia of the genset response characterizations must be
• Acceleration of the motor and compared to the equipment that will
its load (motor characteristics) be used at the facility; this will
ensure the genset is sized to the
• Electrical components loads that will be applied.
between the genset and
motor. Refer to the Motor Loads and
Motor Performance Sections on
Pages 41 & 46 for more information.
Block Load Transient Response Standards

A block load refers to the There are standards in various
percentage of rated power at rated countries; and industries that require
power factor instantaneously added generator sets to be capable of
to the genset. When block loads are accepting and recovering a full load
large, sometimes they should be step. However, many do not specify
accepted in smaller portions in frequency and volt deviations. ISO
various steps. Step loading is very 8528 has set transient response
common when load acceptance standards. Four performance classes
performance criteria are required. For are designated in ISO 8528-1-7 to
example, if a genset is rated 1000 describe a genset in terms of voltage
ekW at 0.8 pf and a 250 ekW load and frequency. The chart below lists
at 0.8 pf is applied to the genset, a the performance class and their
block load of 25% [(power criteria and application examples.
applied/rated power) x 100%] is The performance class relevant for
applied. the application must be followed to
be within the standard and achieve
maximum performance.
G1 Required for applications where the General purpose

connected loads are such that only basic applications Lighting &
parameters of voltage & frequency need electrical loads
to be specified.
G2 Required for applications where the Lighting systems,
demand on voltage is very much the same pumps, fans and hoists
as for the commercial power system.
When load changes, temporary deviations
in voltage and frequency are acceptable.
G3 Required for applications where the Telecommunications
connected equipment may make severe equipment
demands on voltage and frequency and
waveforms.
G4 Required for applications where the Data-processing &
demands on voltage, frequency, and Computer equipment
waveform are extremely severe.
Table 4 shows the acceptance necessary measures but are not

(dip) and rejection (overshoot) helpful when comparing engines of
parameters identified by ISO 8528- different sizes and designs. Instead,
5. Class G4 is reserved for limits engines can be compared by
that are unique and must be agreed referring to their brake mean
upon by the manufacturer and effective pressure (BMEP).
customer. ISO 8528-5 also sets The “mean effective pressure” is
limits on recovery times for each an average of the pressure that
class and identifies how recovery would need to be present in the
time is measured. engine’s cylinder for the power and
torque to be produced. BMEP refers
Agreed between Manufacturer to the brake MEP or the useful work
and Customer (AMC) done at the engine flywheel.
Class Class Class Class
G1 G2 G3 G4 BMEP is an indicator of how much
Frequency %
–15 –10 –7 AMC
engine torque is available. The BMEP
Acceptance can indicate if the pressure within
Frequency %
18 12 10 AMC the cylinder is within the optimal
Rejection
Voltage % performance parameter. BMEP is a
–25 –20 –15 AMC relative number that is only used as
Acceptance
Voltage % a standard to compare engines of
35 25 20 AMC
Rejection different designs or sizes. It can be
Time Seconds 5 5 3 AMC expressed in psi, kPa or bar.
Table 4 BMEP Load Step
Two engines of different sizes are
working similarly if they operate at
SAE Standard J1349 specifies inlet the same BMEP.
air and fuel supply test conditions. It A BMEP load is described in the
also gives a method for correcting following figures and text.
observed power to reference Step-by-Step Events — Load Applied
conditions and a method for Figure 5 and Figure 6 illustrate full
determining net full load engine load addition to a genset with a
power with a dynamometer to turbocharged-aftercooled (TA)
engines. engine, and a 1:1 Volt/Hz voltage
Engine Considerations regulator. Figure 5 shows how the
parameters vary as a function of
Brake Mean Effective Pressure
engine speed; Figure 6 presents the
(BMEP)
same events versus time.
When sizing a genset, comparing
engines may be necessary to Note: Reading through this topic,
determine optimal performance, prior to reviewing the figures, will
especially when motor starting. Both aid in understanding the content.
torque and horsepower are
Figure 5
1. Point 1 is the beginning of the rack stop, the additional fuel

event. The genset is stable at results in overfueling, smoke
no-load, BMEP is zero, and and loss of power.
speed is at high idle. Full load is 5. At point 5, the governor
applied instantaneously. reaches the rack stop and
2. Speed falls and the governor overfueling no longer increases.
increases fuel flow, increasing 6. The turbocharger accelerates,
engine output BMEP. As speed increasing airflow and engine
error and time increase, the power using some of the excess
faster the governor increases fuel. Since the turbocharger is
BMEP. so much slower than the
3. At point 3, the engine reaches governor, power increases much
an equivalence ratio of 1.0, and more slowly.
power temporarily reaches a 7. At point 7, engine output BMEP
maximum. The time is so short finally matches the load
that little turbocharger demanded by the generator.
acceleration has occurred. Since power and load are
4. As the governor continues to exactly equal, there is no
increase fuel flow towards the acceleration or deceleration, and
speed is constant for an instant speed is still below rated. Power

at the maximum speed dip. is now fuel limited.
8. Since the speed error is still 10. The engine continues to
large, the rack is still wide open. accelerate, with BMEP limited
Engine BMEP continues to by the rack stop, as the load
increase, exceeding the BMEP line rises to meet it.
demanded by the load. The Acceleration slows because the
excess BMEP permits the excess BMEP is decreasing.
genset to accelerate, increasing 11. Speed reaches rated, and the
speed towards rated. Power is governor reduces fuel input until
still air limited. engine BMEP output exactly
9. At point 9, engine BMEP matches the load BMEP
reaches its maximum level at demand. Speed becomes
the engine lug curve, although constant again at the new load.
Figure 6
Since only governor action is Explanation of Figure 7

required, the engine can reach point Using Figure 7, the number of load
3 in about 0.2 seconds. The BEMP steps needed for desired power can
of TA engines can reach, be determined. First, find the BMEP
approximately, 140 psi without of the engine at rated speed; BMEP
requiring turbocharger response. levels are shown for each rating in
Thereafter, turbocharger acceleration the performance data of the TMI.
will allow engine BMEP to increase, If the percentage of block load is
roughly, 20 to 60 BMEP per second; under the first load step curve, the
predicted turbocharger response is block load can be accomplished in
modified for engine underspeed one step.
error, overfueling, altitude, cold start
If the percentage of the block load
and air impingement. Given the 20
is greater than the first load step
to 60 BMEP per second increase, the
curve but smaller than the second
example requires approximately 1.5
load step curve, it will take two load
seconds to reach point 7, and
steps to reach desired power.
approximately 4 seconds to reach
point 9. If the percentage of block load is
greater than the first two load step
As engines of a given displacement
curves but less than the third load
are designed for higher and higher
step curve, it will take three load
outputs, their capability to accept
steps to reach desired power.
block loads does not increase.
Although a turbocharged engine can Caterpillar gensets are similar to
produce more power than a similar class G2 of the ISO standard 8528-
displacement naturally aspirated 5. Class G2 gensets must:
engine, its capability to accept block • Accept any load on the curves
loads does not necessarily increase. • Not deviate more than 12% of
The ISO (International Standards rated frequency
Organization) Standard on Generator
Sets has considered this • Not deviate more than 25% of
phenomenon and the data in Figure rated voltage
7, from ISO 8528-5, is the result. • Recover to rated limits within
5 seconds.
Load blocks and response to block
loading is one of many
considerations when sizing a
generator set. Many turbocharged
and aftercooled four-stroke diesel
engines will not accept 100% block
load in one step. Always investigate
Figure 7 to ensure the selected generator set
will meet application requirements.
Engine Configuration the ability to decrease the transient

The way an engine is configured response by increasing the number
can affect the size of genset needed. of turbochargers. This would allow
Air System the engine to run at the same BMEP
The load acceptance behavior of but have a different transient
an engine also depends on the type response. Inlet air pressure in a
of air supply to the combustion turbocharger affects the air density
system. Maximum engine power as well. A smaller nozzle in the
may be airflow restricted. Power can turbine housing of a turbocharger
only be increased if airflow and fuel increases air velocity which causes
rate are increased. Engine airflow is the turbocharger to operate at a
determined by displacement of the higher speed, thus, increasing boost
engine, engine speed, and engine and airflow. An engine equipped
inlet air density. More dense air with water-cooled exhaust manifolds
allows the generator set to perform will transfer less heat to the
more efficiently; thus a quicker turbocharger, making it less efficient
response to varying loads. during short periods of acceleration.
For a given displacement, or given Gas Engines

size of engine, more speed produces Caterpillar gas engines are
more airflow. The best way to naturally aspirated (NA) or
increase airflow at speeds which are turbocharged-aftercooled (TA).
compatible with 60 Hz or 50 Hz is to Atmospheric conditions affect the
increase the density of the air way an NA engine can draw air into
entering the cylinders. A its system. An NA engine’s load
turbocharger can increase pressure capability is directly affected by
which will increase density. Density altitude and ambient temperature.
of the air can also be increased by TA engines have a turbocharger
cooling the hot, compressed air with which compresses air which
a heat exchanger called an increases its temperature. A
aftercooler. A separate water separate aftercooler is used so that
supply, jacket water, or radiator air density and detonation margin is
airflow can be used for this cooling. increased. TA engines can be
derated so that they will not
The configuration of the air
experience premature detonation.
systems can also have an effect on
the transient response. A Block Load and Transient Capability
turbocharger equipped with a The block load capability or
wastegate allows a larger transient response of the gas engine
turbocharger to be used but limits genset package is less than its diesel
the turbo boost pressure under engine counterpart. Most of this
normal operating conditions. The difference is directly attributed to
engine runs faster and therefore the inherently different fuel systems
increases airflow without of the two engines. When the
overspeeding. Another example is governor calls for more power, a
diesel engine reacts by adding fuel deviation and recovery. The power
directly into the cylinder. This produced by the generator is
method permits the diesel engine to controlled by excitation of the rotor.
accept 100% block loads with The voltage regulator controls
acceptable voltage dips and excitation (DC current).
frequency changes. When the Increased load draws more current
governor on a gas engine calls for from the generator, which causes
more power, the throttle opens and the generator voltage to drop. As a
a larger flow of air/fuel mixture response, the regulator increases
starts moving through the rotating field excitation which
aftercooler core, air intake manifold, increases its flux. This increase of
and then into the cylinder. This time flux brings the stator voltage back
delay detracts from the gas engines up. Thus, the generator can produce
capability for accepting large block the higher current and power
loads. demand at the same voltage.
Considerable effort has been made As discussed earlier in this section,
to improve the transient electrical maximum generator power is limited
performance of the G3516B and by temperature. Heat is produced in
G3516C generator sets. The the winding by current flow and
G3516B uses transient richening. magnetic flux changes.
Transient richening is factory- Temperatures above certain
programmed to the control software parameters cause the generator to
that improves block load pick up. exceed its design limit. The best
There is also a bypass line from the method for increasing generator
aftercooler to the inlet of the power without excessive heat is to
turbocharger which is equipped with make the generator bigger; more
an electronic valve. This system is copper (windings) can carry more
called the turbocharger bypass current without raising the
which, in conjunction with factory- temperature; more iron (laminations)
programmed software, allows block can handle more flux without
unloads to be accomplished without increasing temperature.
turbocharger surge (rapid speed
When a load is added, the
change of the turbocharger). These
generator voltage drops as magnetic
two systems enable the G3516B
flux changes in the iron and air gap.
gensets for island operation. The
A bigger generator has more iron, so
G3516B gensets are able to accept
the flux deviation and voltage
10% transient load steps. The
deviation from a given kW is less.
gensets are able to reject transient
load steps up to 25% of rated power The sum of the time constants of
from any given load point. the voltage regulator, exciter, main
rotor and main stator determine the
System Interaction
voltage response and recovery;
The generator and voltage
typically, this is less than one
regulator are responsible for voltage
second, with additional time for the Volts/Hz schedules voltage

regulator to stabilize. proportionally to speed.
Voltage Regulators If the speed dips 15%, the
The voltage regulator is a key Volts/Hz regulator will cause the
component in determining the voltage to dip by 15%. This will
amount of voltage/frequency reduce current flow into the load by
deviation and recovery time. There 15%. The kW absorbed by the load
are several different types of is then 0.85 (85% of volts)
regulators: multiplied by 0.85 (85% of current),
or 72.25% of rated power. The
• Constant
engine only has to produce 72.25%
• Volts/Hertz of rated hp. Mathematically, the
• 2 Volts/Hertz formula for this concept is:
• Digital Voltage Regulator 0.85 volts x 0.85 current = 0.7225 power =
(adjustable Volts/Hz) 0.85 speed x 0.85 torque
A constant voltage regulator Technology has allowed an
attempts to maintain rated voltage increase in engine ratings. This
as the load is applied. Since the increase creates the possibility of
generator is maintaining rated more severe transient loading. In
voltage, it is maintaining applied load some cases a Volts/Hz regulator
(ekW). We previously highlighted the cannot prevent excessive frequency
relationship between ekW and bkW. dip because of large load changes;
bkW = Speed x Torque/lambda the torque has increased so much
the deceleration on load is extreme.
Therefore, when a constant Caterpillar has developed a 2
voltage regulator is used, it imposes Volts/Hz regulator to address this
increasing torque on the engine situation.
during frequency dips. Since most
genset engines are not designed for The 2 Volts/Hz regulator decreases
increasing torque, significant voltage at twice the rate of
amounts of frequency dip can occur. frequency dip. At 15% engine
speed, the voltage would dip to
Engine speed rpm decreases as 30% (2 x 15%) and the load would
any load is imposed on a limited bus be reduced to 70%. The kW
(generator). This causes absorbed by the load is then 0.70
frequency/voltage to dip accordingly. (70% of volts) multiplied by 0.70
Greater loads applied to the genset (70% of current) or 49% of rated
will impose a greater percentage of hp.
dip; greater loads will also require
more time for the engine to recover. If the genset is large enough to
carry the running load the 2 Volts/Hz
The “Volts per Hertz” (1:1 regulator may help in motor starting.
Volts/Hz) regulator was designed to A reduced motor starter may not be
impose a decreasing torque on the required with the 2 Volts/Hz
engine during frequency dips. The regulator when starting large motors
depending on system design and generator set to function in a more

applied load steps. However, the efficient manner and to provide
entire connected system would have improved performance to the
reduced voltage, not just the motor. customer.
Digital Voltage Regulator The digital voltage regulator can be
The digital voltage regulator is a software configured to optimize the
microprocessor-based voltage transient response of any Caterpillar
regulator. Its main purpose is to generator set package by changing
regulate output voltage of an engine the underfrequency characteristics
generator set. It is designed to as well as the control loop gains.
improve performance by allowing The microprocessor-based design
regulation characteristics to be allows for unmatched flexibility in
modified that were previously not diverse applications.
modifiable. This allows the engine
Customer Requirements
graph a complete year and determine
Power Demand any seasonal variations.
On Site Power Requirement A daily chronological load curve,
Before selecting an engine model illustrated in Figure 8, shows load
and rating, a load analysis needs to demand throughout the day. A
be performed. This section will chronological curve establishes the
consider the factors which affect peak daily demand and an energy
generator sizing including load usage profile which can aid in the
management needs, voltage and selection of an appropriately sized
frequency dip limitations, motor engine. This load curve is also useful
starting considerations, start-up in programming units for economical
needs and all required standards. operation.
Load Management
Load management is the deliberate
control of loads on a genset and/or
utility to have the lowest possible
electrical costs.
Assessing the customer’s load
profiles is a key component to
establishing their load management
profile and ultimately the size of
genset needed to operate within that
profile.
Loads Profiles
The duration and nature of a load
must be established to select and Figure 8
operate a genset system at
maximum efficiency. To analyze a Daily typical peaks for various
load, a family of load profile charts is industries can be graphed based on
necessary. Chronological and typical loads as shown in Figure 9.
duration load profiles best serve this
purpose.
Note: Unless the load is known to be
steady, this average cannot be used
to establish the engine and generator
requirements because the average
will always be lower than the Figure 9
maximum kW demand.
Duration curves, as shown in
The purpose of the monthly Figure 10, rearrange chronological
average number is to be able to curves and summarize daily load.
Such curves are developed for a For existing loads that are served
week, month, season or year. The by a utility, power bills or power
daily chart represents the average consumption records will provide the
kilowatt load for each day, while the needed data for a twelve-month
twelve-month chart, shown in Figure period. The average kW load can be
11, represents the average kilowatt determined by the following
load for each month. equation:
Average kW Total kW used in Month
=
Load for Month Total Monthly Hours of Operation
Figure 10
Figure 11
Estimating Load Data (VA/FT2). In a commercial building,

Obviously, historical load data does lighting loads typically range from
not exist for a plant or facility not 1.0 VA/FT2 in a storage area to 15.0
yet constructed. Table 5 estimates VA/FT2 or more in an office area.
the average load of various facilities. Power loads involve loads other
While these numbers will have than lighting. Examples are motors,
variations depending on site furnaces and rectifiers. Unlike
conditions, they are reliable and lighting loads, power loads vary
helpful in making preliminary based on a variety of factors; these
feasibility studies for installation. including start and stop times,
Categorizing Loads percentage of output and the
When developing a load estimate, associated power factor.
it is helpful to categorize lighting and In addition to categorizing the
power loads. These loads are loads, lighting and power loads are
distinctly different. also estimated separately. The loads
Lighting loads are relatively are later combined to determine the
constant. They are most often approximate total load.
expressed as load density in volt-
amperes (VA) per square foot
Load and Power Consumption Estimating Data

Power Usage
Facility Watts/sq ft kWh/ft2/yr
Schools 4-5 average (43.06-53.82 W/m2 (Total) 11 to 17
Class Rooms 5-6 (53.87-64.58) (1.02 to 1.58
Locker Rooms, Auditoriums, 2-3 (21.53-32.29) kWh/m2/yr)
Halls and Corridors 20 Watts per running foot (65.62 W/m)
Shopping Centers 5 average (Total) 28 to 34 (2.6-3.2)
Stores, Large Department and Specialty Stores 5-6 (53.87-64.58)
Show Windows 500 Watts per running foot (1640.5 W/m)
Office Buildings 5-6 average 28 to 34 (2.6-3.2)
Private and General Offices 4 (43.06)
Professional Offices 6-7 (64.58-75.35)
Dentist, Drafting Rooms, etc. 7 (75.35)
Hotels and Motels 3-4 average (32.29-43.06) (Total) 12 to 17 (1.1-1.58)
Lounge 2 (21.53)
Rooms 3 (32.29)
Dining Rooms 4 (43.06)
Exhibition Halls, Shops, Lobby, Kitchen 3 (32.29)
Hospitals 1.5 to 2.5 kW per bed average 8500 to 11400 kWh
Lobby, Wards, Cafeterias 3 Watts/sq ft (32.29 W/m2) per bed per year
Private Rooms, Operating Rooms 5 Watts/sq ft (53.82 W/m2)
Operating Tables: Major Surgeries 3000 Watts each
Minor Surgeries 1500 Watts each
Apartment Houses 2-3 kW per unit (Total) 11 to 17 (1.20 to
Lobby 2 Watts/sq ft (21.53 W/m2) 1.58)
Apartments 3 Watts/sq ft (32.29 W/m2)
Small Appliances 1.5 kW/unit
Table 5
Load Example
2
VA/FT Load Estimating Calculate the load for a 10,000
For estimating purposes, power square foot office with electric air
loads and lighting loads can be conditioning.
measured in VA/FT2. However, a Solution
detailed analysis requires individual The left-hand column of Table 6
measurement of power loads to indicates the maximum lighting load
ensure accuracy. in an office building is 4.0 VA/FT2.
A simple table, based on VA/FT2, Therefore, the lighting load equates
is used to obtain a rough estimate of to:
a load as expressed in total kVA 4.0 VA/FT2 x 10,000 (square feet) = 40,000 VA
generated; Table 6 shows such a
table.
Volt Amperes Per Square Foot (VA/FT2)

Load Type
Facility Type Miscellaneous Air-Conditioning Air-Conditioning
Lighting
Power (Electrical) (Non-Electrical)
Office Building 2.5 - 4.0 2.0 4.0 - 7.0 1.5 - 3.2
Hospital 2-3 1.0 5.7 2.0 - 3.2
School 2.0 - 4.0 1.5 3.5 - 5.0 1.5 - 2.2
Table 6
Reading the table from left to right: earlier in this guide, is one system
2
2.0 VA/FT is required for for developing a starting method.
miscellaneous power loads: Most loads do not draw power in a
2
2.0 VA/FT x 10,000 (square feet) = 20,000 VA steady-state fashion; therefore, it is
important to know the operating
sequence and what else is running
7.0 A/FT2 is required for electrical when loads are connected.
air conditioning loads:
7.0 VA/FT2 x 10,000 (square feet) = 70,000 VA
Prioritization
Prioritization is the process by
which the customer identifies what
Add the individual loads to electrical loads are needed and in
determine the combined load: what priority. The highest priority
40,000 + 20,000 + 70,000 = 130,000 VA loads would be in the first step;
even if all the gensets are not ready
for load. The first genset ready to
When using the table, it is
accept the load would take the first
important to remember that the table
priority loads. The next step would
does not account for power losses
go to the next highest prioritized
caused by the resistance found in
load. This process will repeat until all
wires and cables. A power loss of
loads are applied.
up to 6% would be factored into the
VA total when estimating a facility Smaller load steps equate to
with extensive wiring. smaller transients, which result in a
smoother transition. For example, a
Load Steps medical center might prioritize
Load steps refer to the amount of lifesaving equipment as their number
load that will be placed on a genset one need. That equipment (or special
at one time. A genset may accept outlets for that equipment) would be
load in one load step, or may spread the first supplied with electricity
it out over several load steps. The from the first available genset.
customer can identify the needs of Lights may be identified as the
the environment and then a proper second most important need and
method of starting can be applied. handled by the second load step.
BMEP load step analysis, described When starting generator sets
without a preferred load order, it is
suggested that the largest loads are consultants, customers and

started first. The largest transient contractors will determine categories
will occur before the system is for loads based on each project.
heavily loaded. These large loads will For example: Loads on a project
have the least effect on the rest of may be divided into lighting, heating
the system. and cooling loads. On another
Load Shedding project, the loads may be
Load shedding refers to the categorized as normal, emergency
method by which needs are and uninterruptible loads. The loads
prioritized after the gensets are on a third project may be labeled as
started. During periods of high base, intermediate and peak shaving
demand, some loads may be less loads.
important to the facility than other Load Management Strategies
loads. These can be “shed”, or not Power utilities sometimes offer
powered, so the electricity can be their customers power discounts if
used for predetermined, essential their loads do not fluctuate or
loads. exceed a certain limit. The most
For example: In a factory, all common are peak shaving, base
welding equipment and other loading and zero import/zero export
machines may be operated, at control.
capacity, at the same time, between Peak Shaving
10 am and 12 noon and then again Figure 12 shows how a utility
between 1 pm and 3 pm. During customer can qualify for a
these times, the load to lights in the discounted rate by not allowing the
lunchroom and parking lot would be power demand to be above 500 kW.
shed because they are less of a Any power generated over 500 kW
priority.
is supplied by the customer’s
Intermittent Loads generator. Thus, the customer
Equipment, such as furnaces and “shaves” the peaks from the
elevators, use power intermittently utilities’ responsibility. Peak shaving
and are considered intermittent can be very demanding on an
loads. engine; it must be able to start
All loads that follow an quickly and automatically parallel to
intermittent load must consider the the utility. The response time of the
intermittent load as part of its total. engine is crucial because of the load
This increases skVA requirements fluctuations.
and a larger generator may be
needed to account for intermittent
loads.
Additional Load Categories
There are no official guidelines for
categorizing loads. Architects,
Zero Import/Zero Export

The load management type in
which the customer supplies all the
electrical needs to the facility, while
still paralleling with the utility is
called Zero Import/Zero Export
control. Refer to Figure 14. If the
power requirements fluctuate
Figure 12 widely, a series of generator sets
can be used and brought on-line as
Base Loading required. Since the customer
The least demanding power remains paralleled to the utility, the
management type on an engine is demands made on the engines for
base loading. The generator operates this type are similar to base loading.
at a constant load and the utility Reliability is the chief concern for
imports power when the load these customers. Utilities will often
exceeds the generator output. The invoke demand charge penalties
user can also export power to the each time they are called upon to
utility if the load is below the output supply power.
of the generator. Figure 13 shows a
base loading system and indicates
when power would be imported or
exported. Since overloads are
handled by the utility and the
generator set is operating at a
constant load, size and engine
response time are not as crucial as
in peak shaving.
Figure 14
Figure 13
Concepts of Peak Shaving vs. Peak Sharing

Peak Shaving Peak Sharing
Customer sheds load or generates power to Customer generates power to help utility
reduce own demand peak reduce its peak
Practice is generally discouraged by utility Practice encouraged by many utilities with
companies generating capacity shortfalls
Customer benefits at utility’s expense in lost Because the utility benefits, it can afford
sales to reward the customer
Customer savings accrue from reduced Savings accrue from interruptible rates or
demand charges credits per kW of customer’s on-site
generating capacity
Concept is feasible only where customer Concept is viable even for customers with
experiences severe demand “spikes” and relatively flat load profiles
high demand charges
Customer decides when to run generators Utility dictates operation when utility
cannot meet all of its customers’ demands
If generators are installed for the sole purpose of taking advantage of peak-shaving
incentives, the customer gains the additional benefit of acquiring backup protection
against utility outages
Figure 15
Peak Sharing utility or in parallel so the

In a typical peak sharing cogenerator can purchase from or
arrangement, the customer installs sell power to the utility.
and operates generators of specified Load Duration Curves
capacity when directed to do so by Load duration curves can also
the utility company. Under many represent loads.
peak sharing contracts, utilities
compensate the customer for each
time they operate their onsite
generators. The differences between
peak shaving and peak sharing are
outlined in Figure 15.
Co-generation
Co-generation is the term used to
describe the load management
system that produces electricity for
lighting and equipment operations
while at the same time it utilizes the
waste heat produced in the exhaust
Figure 16
for heating, cooling, or generation of
process steam. Co-generation plants
can operate independently of the
As shown in Figure 16, loads are horsepower hour (BHP) of an air

arranged into descending order of compressor, rated at 125 psi, can be
magnitude based on the percentage found by multiplying the rated cubic
of the total load. Generator sets feet per minute (CFM) of the
powering the base load operate for compressor by 0.275. Fans,
the duration of a 24-hour period. blowers, inclined conveyors, and
Generator sets powering the welders can also be estimated using
intermediate load are activated for a the information in this chart.
limited period when the load Load Growth
increases to a specified level.
The customers’ future needs are to
Generator sets earmarked to power be taken into account when sizing
the peak load are used to help power the generator set. If the customer
100% of the load for a short period. anticipates growth in their
Knowing the type of load application due to increased volume
management that is most or expanded needs, oversizing the
economical to a facility can help engine or leaving room for another
determine the size of genset needed generator to be installed at a later
based on the load factor and date is reasonable and helpful to the
application. customer. The projected load growth
for any application should never be
Estimating Guidelines
less than 10%. Table 8 shows
Many guidelines can be used for
typical load growth over a period of
estimating the varied types of loads.
10 years for various applications.
For example: In Table 7, the brake
Typical Load Sizing Guidelines

Inclined Conveyors
Air Compressors Fans & Blowers Welders
(15° to 20°)
90 psi rating:
Light Duty:
0.225 CFM = BHP
3 to 20 kW
100 psi rating: CFM x in H2O Ft. Vertical Lift x Tons/Hr
0.25 CFM = BHP BHP = BHP =
6,346 x EFF. 500
Heavy Duty:
125 psi compressor:
20 to 100 kW
0.275 CFM = BHP
Table 7
Load Growth Over 10 Years

Bank Medical Center
30 – 50% 30 – 50%
Church School
30 – 50% 30 – 50%
Hospital Warehouse
30 – 50% 30 – 50%
Table 8
on the system is 15 kW, which is

Demand Factor also the same as its connected load.
As mentioned, the load The operating load of the 100 hp
requirements must be defined as motor, operating at 87% of its total
accurately as possible to determine capacity, is 65 kW.
the best size of genset needed. The
“maximum demand” or “demand Example:
factor” is the highest demand which What is the demand factor of the
is placed on the supply within a system shown in Figure 17?
specified period of time. After the Solution:
total connected load has been To calculate the numerator add the
found, it is important to know how individual kW loads:
much of the maximum load will 20 + 15 + 65 = 100 Operating kW Load
actually be used at a given time.
Another way to describe demand
factor is the mathematical ratio of For the denominator add the hp
the operating load divided by the ratings for each motor:
connected load. 50 + 20 + 100 = 170 hp Total Connected Load
Total Operating kW
X 100 = Demand Factor
Total Connected kW The conversion factor for hp to kW
is 0.7457 or 0.746. Therefore, total
connected load is multiplied by
0.746 to get 126.82 kW, or 127
kW:
0.746 x 170 = 126.82 = 127 kW)
To find demand factor use the

Figure 17
formula:
Figure 17 also illustrates demand Total Operating kW
X 100 = Demand Factor
factor. On this system, three Total Connected kW
motors, rated at 50 hp, 20 hp and
100 hp each, are connected to a 100 kW
X 100 = 79%
generator set. 127 kW
If the 50 hp motor were operated
at 100% capacity, its total
connected electrical load would be
37.3 kW. However, the 50 hp motor
is only expected to produce 54% of
its total capacity. Hence, the
operating electrical load is 20 kW.
Operating at 100% capacity, the
maximum load of the 20 hp motor
Shown in Table 9 is a range of Figure 18 can be used to illustrate

common demand factors. diversity factor. It is important to
Range of Common Demand Factors know how much of the entire
Total Connected system’s maximum load present at a
Apparatus given time. As shown in Figure 18,
Load
Motors for pumps, individual loads are connected to
compressors, load centers. The load centers have
20 to 60 Percent
elevators, blowers, 20 kW, 15 kW and 65 kW loads
etc …
Motors for semi-
each, for a total connected load of
continuous 100 kW. The 100 kW total
operations, such as 50 to 80 Percent connected load is routed to an 80
process plants and kW meter.
foundries
Arc welders 30 to 60 Percent To determine the diversity factor
Resistance welders 10 to 40 Percent of the system shown, 20 kW, 15
Heaters, ovens, kW and 65 kW are combined to get
80 to 100 Percent
furnaces a total connected load of 100 kW.
Table 9 To find the diversity factor use the
formula to solve:
Diversity Factor Total Max. Demand kW
X 100 = Diversity Factor
Diversity factor is the value placed Total Incoming kW
on a small collection of loads. The
value for the whole system itself, 100 kW
which is comprised of smaller X 100 = 125%
80 kW
collections of loads, is called the
diversity factor. Specifically,
Typical diversity factors include:
diversity factor is the mathematical
ratio of a system’s individual • Lighting feeders:
maximum demands divided by the 1.10 to 1.50%
maximum demand of the system as • Power & light feeders:
a whole. The formula used to 1.50 to 2.00% or higher
calculate diversity factor is total
maximum demand divided by total Demand Factor and Diversity
incoming kW times 100. Factor in Sizing
Total Max. Demand kW Demand and diversity factors are
X 100 = Diversity Factor advantageous when sizing generator
Total Incoming kW
sets to the load.
However, the connected loads
should be interlocked so that they
cannot all be impressed upon the
generator set at the same time. If
the loads are not interlocked, the
generator set rating could be
Figure 18 exceeded. Despite this precaution,
you must always assume that total kVA. Hence, a generator set rated at
time-current characteristics of all 500 kVA would satisfy the load.
motors and other loads starting at In summary, all loads need to be
the same time will not exceed the analyzed so that the correct size
short-term generator set rating. generator can be matched to the
Figure 19 illustrates how demand load. When sizing a generator for an
and diversity factors are used in application, the steady state load
generator set sizing. and maximum transient load need to
be considered.
Frequency Dips
Frequency dips are related to the
size of load being connected.
Twenty to 25% maximum frequency
dip is the standard limit. A frequency
dip above 35% may cause the
engine difficulty in recovering.
Frequency dips are normally more
tightly controlled than voltage dips
because they are typically connected
to more sensitive electrical
equipment.
Figure 19
Block Load & Standards
The NFPA (National Fire Protection
Association) standard 110 requires
In Figure 19, connected loads of
that a generator set must be capable
300 kVA, 100 kVA and 500 kVA
of picking up a 100% block load. It
are shown. After calculating demand
does not specify frequency and volt
factors for each of the same loads,
deviations.
the corresponding demand loads are
240, 100 and 350, respectively. ISO 8528 (2005) also has
When combined, the total demand transient response standards that
load on the system is 690 kVA. are discussed in the Engine Ratings
When the diversity factor is 1.0, the section of this guide. The
total 690 kVA is divided by 1.0 to performance class relevant for the
get 690 kVA. To meet this load, a application must be followed to be
generator set rated at a standard within the standard and achieve
size of 750 kVA is needed. maximum performance.
However, a different diversity Starting Requirements
factor on the same system will The time it takes to initiate a
change the total kVA needed. If the genset startup and when it is ready
diversity factor is 1.4, for example, to accept load is defined as its
690 kVA divided by 1.4 equals 492 starting requirement. Starting
requirements will vary depending on
the application. A typical starting and maintain a 100 psi (689.5

requirement is 10 to 30 seconds. kPa) minimum pressure.
Load Acceptance 2. Combustion air must be a
Load Acceptance is the point at minimum of 21°C (70°F).
which breaker closure is initiated. 3. A jacket water heater to
This is considered to be 90% of maintain a minimum of 32°C
rated frequency. Figure 20 (90°F) jacket water
graphically shows a packaged temperature.
genset’s typical starting 4. A readily available supply of
performance. clean fuel.
5. The generator rotating inertia
must not exceed that of the
standard Caterpillar Generator.
Any variation in these conditions
will affect the start time.
Natural Gas Engines
Special engine conditioning is
required for a natural gas engine to
start in 10 seconds. Ten-second
starting is only possible on specific
Figure 20 gas engines. Consult the factory for
specific engine model starting
requirements.
Ten-Second Start Starting condition requirements for
Ten-second start refers to the natural gas engines are the same as
ability of a non-paralleled generator diesel engine starting requirements,
set to start, accelerate to rated except for one detail: The solenoid
speed and be ready to accept load gas valve must be located as closely
within 10 seconds after receiving a as possible to the carburetor or “A”
signal to start. regulator, depending on the fuel train
For 10-second starting, the consists. A maximum distance of
following conditions must exist: 0.61 m (2 ft) is desired.
1. Cranking batteries must be A customer’s starting time
adequately sized and fully requirements should be determined
charged. before sizing the genset. A quick
Note: there is a difference for starting application requires
battery versus ambient consideration of altitude,
temperature sizing. temperature and other factors that
Also, in cases where air starting affect the engine starting to find the
is used, the air system must best solution.
supply the required air volume
Refer to Emergency & Fast Natural Gas

Starting in the Starting Systems Natural gas engines are appropriate
Application and Installation Guide for for base loading, continuous
more information. operations. Natural gas does not
respond well to transients so it
Health Care Facilities & NFPA 99
would not be a good choice for
The standard NFPA 99 is written
specifically for health care facilities. loads with fluctuations. Natural gas
can be less expensive, depending on
3-4.1.1.8 states the following: availability, and it has superior
“The generator set(s) shall have emissions.
sufficient capacity to pick up the
load and meet the minimum Diesel
frequency and voltage stability Diesel fuel is suited for large load
requirements of the emergency fluctuations. Fuel normally
system within 10 seconds after loss recommended for diesel generator
of normal power.” sets is No. 2 furnace oil or No. 2D
diesel fuel. When this fuel is used
Customers requiring this capability
for heating, common storage tanks
can achieve it by using the correct
for boilers and generator sets are
generator system. Select an
practical. In addition to reducing
appropriate genset according to this
installation costs, this arrangement
standard for all health care facilities
reduces fuel costs by quantity
in the United States.
purchases and minimizes fuel
Sizing a genset requires knowledge deterioration. Diesel is an excellent
of the customer’s loads and load choice for base loading and standby
management strategies as well as applications.
their requirements for transient
Heavy Fuels
response, emissions and starting. All
Heavy fuels are the by-products
these requirements need to be
from the refining process of oil. It is
determined before the genset size
and rating are established. extremely viscous and the fuel
quality is low. However, this fuel is
Fuel Selection very inexpensive. For industries
Fuel selection can impact the which burn large amounts of fuel,
performance of a genset and, heavy fuels are a choice to consider
depending on availability, reduce because of their economic
electricity costs for a genset user. advantages. Heavy fuels are not a
Natural gas, diesel and heavy fuels good choice for standby
are common choices. applications.
Note: Detailed information on
gaseous fuels and diesel fuels is Performance
available in respective Application & Emissions
Installation Guides. Standards on engine emissions are
constantly evolving.
Special engine configurations allow The sulfur present in the fuel

operation with lower exhaust oxidizes to form sulfur dioxide. The
emissions. Gaseous exhaust emission of sulfur dioxide depends
emissions of diesel engines are the on the amount of sulfur in the fuel
lowest of modern internal and the fuel consumption of the
combustion engines. Engine engine. Sulfur dioxide emissions can
emissions are measured using a be calculated using the following
Horiba or Beckman gas analyzer, formula:
with equipment and data SO2 = (00.01998) (BSFC) (% Sulfur In Fuel)
measurement techniques conforming
Where:
to U.S. Code of Federal Regulations,
Title 40, Part 53 or 86. SO2 = Emissions in g/kW-hr
Caterpillar has developed a BSFC = Brake Specific Fuel
correlation between smoke and Consumption
particulate concentration which can % Sulfur = A percentage by
be used to estimate particulate In Fuel weight
emissions.
Black Smoke Nitrogen oxides are formed when
Black smoke is the soot portion of the combustion air oxygen and
particulates and is caused by nitrogen molecules combine. Nitric
incomplete combustion. Black smoke oxide gradually oxidizes to become
is not considered an exhaust the more harmful, nitrogen dioxide in
emission; rather it is a compilation of the atmosphere. Nitrogen dioxide is
exhaust emissions with particulate a poisonous gas which, when
matter being the largest contributor. combined with hydrocarbons in the
Due to the fuel composition, gas form of sunlight, creates smog.
engines typically do not have
Nitrogen dioxide emissions in parts
significant particulate matter
per million by volume can be
emission and do not emit black
approximated from the mass
smoke.
emission rate and exhaust flow:
White Smoke NOx Mass Emissions
White smoke is caused by NOx Concentration = 629 x
Exhaust Mass Flow
vaporized, unburned fuel passing
through the engine. Like black
smoke, white smoke is not Where:
considered a defined exhaust NOx Parts Per Million
emission. Typically, white smoke =
Concentration
will only be present during startup
NOx Mass g/hr of equivalent
and will fade as the engine jacket =
Emissions NO2
water warms as the engine is
loaded. Jacket water heaters help Exhaust Flow = Kg/hr
reduce white smoke at startup.
Caterpillar offers standard (STD) Nominal vs. Not to Exceed

engines for areas where emission Engine emissions information is
levels allow. A catalytic converter typically published in one of two
can also be added for places where formats. The first is nominal, which
emission standards are more is what emissions levels would be
rigorous. Low Emission (LE) engines expected from a nominal engine;
are for areas where emissions are of while the second level is not to
primary concern. The LE engines use exceed, which is the maximum
lean burn technology. Lean burn emissions output expected for an
means that excess air is forced into engine. It is important to understand
the cylinder to cool the combustion these levels when comparing
process. This process reduces the competitive information and when
NOx in the exhaust. LE engines can providing information to engineering
sustain higher loads without consultants and end users.
detonating. Because of this, LE “Not to Exceed” data includes a
engines have a higher rating than “Tolerance Factor” to account for
STD engines, given the same paralleling and instrumentation and
compression ratio and separate facility variations. If the “Not to
circuit aftercooler temperature. Exceed” value is exceeded during
Some measures that improve field measurements, it is likely that
emissions levels will affect other the test equipment is at fault or that
areas for sizing considerations. the engine has a problem.
Either kW are reduced or the Caterpillar engines, at rated speed,
response rate value may be higher in will not exceed the values specified
some instances. Of course, this can in Table 10.
affect engine ratings and the
performance of the engine.
Diesel Natural Gas
Correction Factors Emission g/bhp-h Catalytic Low
Emission levels are affected by the NA TA T
Converter Emission
engine rating, speed, turbocharger, Nitrogen Oxide
12.0 15.0 19.0 1.2 2.0
timing, fuel and ambient conditions. (NOx)
Higher ambient temperature and Carbon Monoxide
3.5 2.0 1.5 1.0 1.7
higher altitudes increase nitrogen (CO)
Hydrocarbons
dioxide and particulate emissions. 0.4 1.5 1.5 0.5 0.35
(NMHC)
When engines are tested in the lab,
they are tested to specific standards Table 10
outlined in ISO 8178-1 in regards to
Note: Depending on configuration
temperature, barometric pressure
and rating, many engines emit
and fuel density. The nominal level
considerably less emissions. Specific
of emissions data is derived under
emission data is available from the
these conditions. The specific
specific product TMI.
conditions can be accessed through
TMI.
Heat Balance customer in terms of performance.

Before a cooling system is However, if the customer requires
designed, the designer must co-generation capability, it becomes
understand how much heat is being crucial in their application. Btu’s
rejected through each of the cooling must be matched, not just to the
circuits. The following guide will customers overall need, but to their
help interpret and apply the heat specific application need.
rejection data. Many factors about the customer’s
Heat balance is a term used to needs should be considered before
describe the following: determining the best solution.
The heat input into the engine equals the sum of Assume the following situation: A
the heat and work outputs. customer needs 45% Btu’s for heat,
45% for electricity and 10% is lost.
An example of this relationship is
Before selecting any unit that meets
shown in the following equation:
this criteria, additional questions
should be asked and might include
Work Output some of the following.
+ Total Exhaust Heat • Should a genset be offered
+ Radiation that is long on heat capability
and short on electrical
+ Jacket Water
capability with the intent that
+ Oil Cooler the additional electricity
+ Aftercooler needed be purchased from a
= Total Heat Input utility?
• How about a genset that is
long on electrical capability
In every calculation using engine and short on heat?
data, there is a tolerance band or a
deviation from norm. Heat balance • Will that option save the
tolerances must be applied when customer money if a cooling
sizing cooling system components. system is used seasonally or
The tolerances recommended by year round?
Caterpillar vary depending on the • What are the prices for
engine mode and are published in heating and electrical fuel
TMI. from the utility?
Additional information on this • What types of load
subject can be found in the Cooling management options are
Systems Application & Installation available to them?
Guide. In addition, these items should be
Co-generation Usage considered with the customer’s
On a standard engine, the heat current and future needs in mind
balance is not relevant to the before recommending a solution.
Load Analysis
Load analysis is the process of Energy = Power x Time
considering size, starting
characteristics and intended usage
In electric power generation,
of electrical loads and their collective
electrical energy produced or
impact on a generator set power
consumed is expressed in kilowatt-
source.
hours (kW-Hrs). A single kW-Hr of
At times, it may be necessary to energy is one kW of electrical power
conduct a detailed analysis, through used for one hour.
discussion and observation, with the
kW-Hrs = kW x Hrs
user, customer, or
consulting/specifying engineer to
determine the exact nature of the Loads have different electrical
loads. characteristics. When developing a
Determining the electrical load of a load analysis, it is helpful to
facility is the first and most categorize loads into groups with
important step in supplying a common characteristics. There are
generator set. The generator set no rigid standards for categorizing
supplier is looked upon as the expert loads. Architects, consultants,
when it comes to choosing the right customers and generator set
generator set to power the load. As suppliers will determine or speak of
a supplier of high-quality Caterpillar categories for loads based on the
generator sets, it is important to needs of the project involved.
understand electrical loads and For example, loads may be
possess a working knowledge of categorized as normal loads and
basic load analysis. emergency loads or perhaps critical
An electrical load is a device that loads and non-critical loads. There
uses electricity; lights, motors, may be further division of the
heaters, welders and emergency or critical loads into
communications equipment are just additional categories of life-support
a few examples of electrical loads. or uninterruptible loads. On a
different project, the loads may be
It is important to understand the
labeled as base, intermediate and
relationship between energy and
peak shaving loads.
power when discussing electrical
loads. Power is a rate of doing work. Load analysis should define those
It is a product of force and motion. loads that are considered linear
Electrical power is the product of (draw current in a sine waveform)
electromotive force (volts) and and non-linear (draw current in
current flow (amps). It is expressed pulses or non-sine waveform).
in watts or kilowatts. Energy is
work. It is the product of power and
time.
Further definition of linear & non- Lighting Loads

linear loads is included in the Load
Linear Lighting Loads
Type Section on Page 91.
Linear loads are loads that draw
Proper selection of a generator set current in a sinusoidal waveform as
as a power source frequently shown in Figure 20. There are many
requires detail within these examples of linear loads, but lighting
categories of linear or non-linear. In is the most common.
addition, loads can be separated as
lighting loads, motor loads, and
miscellaneous loads. A generator set
is a limited power source,
sometimes referred to as a “limited
bus”. The limited bus does not have
the reserve capability of a utility
grid. It is necessary to analyze and
categorize generator set loads to
assure proper consideration of their Figure 21
power demand characteristics.
Lighting
The loads discussed in this chapter
Lighting loads are typically
are going to be categorized by type
considered a constant load for sizing
and if they are linear or non-linear.
purposes; even though individual
Primarily we are going to separate
light circuits or lamp usage can be
the load as lighting loads, motor
very diverse. Lighting is often
loads, and miscellaneous loads that
expressed in volt-amperes (VA) or
have unique characteristics.
kilovolt-amperes (kVA) because it is
primarily a resistive load with a near
Typical Electrical Loads unity (1.0) power factor (pf).
Lighting Therefore, if a lighting load is given
Incandescent lamps, fluorescent in kVA, it is usually assumed to be
lamps, high-intensity discharge (HID) of an equal kW value. There are
and arc.
Heating
several types of lighting.
Resistor ovens, convection ovens, Incandescent Lighting
dielectric heating, induction heating,
An incandescent lamp has a
arc furnaces.
Welding
filament, which is heated to
Resistance welding, arc welding, incandescence by an electric
and induction welding. current. This is a very simple and
Motors commonplace electrical load.
DC, induction and synchronous. Incandescent lamps are rated by
Miscellaneous
voltage and wattage requirements.
Rectifiers, solid-state controllers and
communications. The power factor is 1.0, so
incandescent bulbs can operate on
Table 11
either alternating or direct current.
These loads are often rated in watts. to the voltage. Non-linear loads
For example, ten 100-watt light create harmonics, or additional sine
bulbs would be a 1000 watt or 1 waves, that are a multiple of the
kW load. Current drawn by a lamp is generated frequency in the current
found by dividing its wattage rating waveform; Figure 21 illustrates
by a specified input voltage: harmonics. This will influence the
A = W/ V generator size. Harmonics are
discussed in detail in the Generator
Incandescents draw high inrush
Systems Application & Installation
currents and are suitable in
Guide (LEBW4993).
applications which require flashing
or dimming, with operation over
wide voltage ranges. Any voltage
fluctuation can affect the lamp
brightness while extreme voltage
fluctuations shorten filament life.
Tungsten Lamp Inrush
Tungsten filament lamps are
resistance devices. The resistance of
a tungsten filament increases rapidly
with an increase in temperature. At
room temperature, with the lamp
“off”, resistance is low. However,
the filament temperature increases Figure 22
rapidly when the lamp is turned “on”
and, consequently, the resistance Fluorescent Lamps
increases as the lamp assumes Fluorescent lamps are also rated by
normal operating temperature. This voltage and wattage. Due to the use
is called tungsten lamp inrush. of a ballast transformer, these lamps
have power factors slightly lower
Tungsten lamp inrush current can (0.95 to 0.97) than incandescent
be up to 17 times greater than the lamps. When incandescent or
normal current but the surge lasts fluorescent type lights operate from
only a few cycles. Switches must be step-down transformers, power
designed to handle such surges. factor contribution of the
When using a generator power transformer must be considered.
source, this phenomenon is generally Uncompensated fixtures can show
inconsequential. However, very large power factors as low as 0.5 lagging.
blocks of tungsten lighting load may
cause a momentary voltage dip Gas Discharge Lamps
transient to occur. Gas discharge lamps are
fluorescent, high-pressure sodium or
Non-Linear Lighting Loads similar lamps which use a gas-filled
Non-linear loads are AC loads in chamber in combination with a low
which the current is not proportional energy, high voltage sustained
electric arc. Gas discharge lamps are As compared to a utility buss feed,
rated by voltage and wattage. an on-site genset is a limited source
The high voltage required by a gas of horsepower, from the engine, and
discharge lamp is obtained by using kVA from the generator. Thus, a
ballast transformers and electronic genset must be large enough to start
ballasts. as well as run connected motor
loads.
Ballast transformers with
saturating reactors are used to Motors convert electrical energy
provide high voltage and control into mechanical motion. They can
lamp current. Current produced by present severe demands on the
this type of ballast is high in third power source during starting and
harmonic content due to the acceleration to rated speed. Current
saturating reactors. Electronic demand can range from four to ten
ballasts use electronic power circuits times normal full load current during
to generate and control the lamp this period. That above normal
current. current demand is called starting
kVA (skVA) and often has great
Like fluorescent lamps, gas
influence on generator selection.
discharge lamps have power factors
slightly lower (0.95 to 0.97) than Starting an electric motor can
incandescent lamps. Gas discharge create voltage dips in excess of
lamps may be sensitive to transient 40% if the genset is not properly
voltage dip. Certain types of gas sized. This can create serious effects
discharge lamps may extinguish on the existing loads such as the
during a severe transient voltage dip dimming or extinguishment of lights
and delays in re-illumination may be or stoppage of motors due to
experienced. Lamp manufacturers or insufficient voltage. The starting of
suppliers should be contacted for motors will be discussed later in this
characteristics. This is not typical of section.
fluorescent lamps. As a rule, avoid Pre-loads on motors do not vary
heavy SCR loads, large block maximum starting currents, but do
switching loads and large motor determine time required for motors
skVA loads on gas discharge lighting to achieve rated speed and current
circuits. and to drop back to normal running
value. If motors are excessively
Motor Loads loaded, they may not start or may
When sizing a genset, it is run at a reduced speed. Both
important to identify the types of starting and running current are
motors being used because of the considered when analyzing total kVA
various starting characteristics. requirement.
Starting characteristics may drive
AC electric motors represent
the need for a larger or smaller
inductive loads with lagging power
generator.
factors between 0.5 and 0.95,
depending on size, type and loading.
With few exceptions, there are Squirrel Cage

two basic types of AC motors: The squirrel cage motor is the
• Induction Motors most widely used of all motors in
industry. Most three-phase motors
• Synchronous Motors
are squirrel cage type. When a
Induction Motors constant speed drive with no
Induction motors, shown in Figure continuous low-speed running is
23, are the most common motors in required, a squirrel cage motor is
use today. Induction motors have a used.
stationary armature connected to the The name is derived from
power source. The rotor winding, construction of the rotor circuit.
with rotating shaft, is excited by Solid conductor bars are arranged
voltage induced from the magnetic around the rotor periphery with their
field developed by the stationary ends short-circuited. If this
armature windings. Voltage, induced conductor assembly were removed
in the rotor, results in current flow from the steel core, it would
within the rotor winding. This resemble the appearance of a
current creates another magnetic circular small animal cage.
field around the rotor conductors. Squirrel cage induction motors are
Rotation of the rotor results from the manufactured with design variants
interaction of rotor and armature for specific performance features
magnetic fields as the armature such as starting torque,
magnetic field rotates around the speed/torque characteristic and
stationary armature with the locked rotor amps. Squirrel cage
progression of AC current flowing in motors are divided into four designs;
the armature windings. A, B, C and D. Descriptions of these
The two types of induction motors classes are discussed in the Motor
are the squirrel cage and the wound Performance section of this guide.
rotor. Table 12 lists the specifications for
each class of motor.
Squirrel Cage Motor Torques in Per Unit

of Full-Load Torque
Locked-
Class Breakdown Pull-Up
Rotor
A 1.40 Over 2.00 1.00
B 1.40 2.00 1.00
Over
C 2.00 1.90
1.40
Not Not
D 2.75
specified specified
Figure 23
Table 12
Wound Rotor (Slip Ring) is in the range of 100% full load

A wound rotor motor is a special current. If all rings were shorted at
induction motor which features a start up, as in a squirrel cage motor,
rotor that is wound with coils. there is zero resistance and starting
Windings are placed in slots around current would be approximately
the rotor periphery and connected to 460% of full load current. This
slip rings. The slip ring brushes are would present a much more severe
then connected to external resistors. starting condition. Normal operation
Changing the rotor circuit resistance of this motor is with all resistance
will change the induced rotor circuit shorted.
current and vary the motor’s
speed/torque characteristics. High
rotor resistance provides a high
starting torque with low starting
current. A wound rotor induction
motor normally has five to seven
steps of resistance in the rotor
circuit.
Wound rotor motors are used for
starting large rotating mass or high
inertia loads with a long acceleration
time. They provide a smooth start
with minimized motor heating during
the acceleration period. Usually the
motors are started near unity (1.0) Figure 24
power factor. Starting current is
limited to 130% of rated operating Slip Definition
current. Because these motors have Speed of an induction motor is
no code letter, exact operating almost constant from no-load to full
performance must be obtained from load in relationship to the supply
the motor nameplate or the frequency. Ideally, if there were no
manufacturer. Typical applications resistance to rotor rotation, the
are large pumps, long conveyers, rotor’s magnetic field would follow
large diameter fans and large exactly in synchronism with the
rotating drum devices. armature’s magnetic field. However,
The characteristics of current are in induction motors, the armature’s
shown in Figure 24, as they rotating magnetic field must cut
correspond to steps in resistance. through the rotor conductors to
Also shown are percentages of total create the torque. In other words, an
rated resistance in the rotor circuit. induction motor must run at less
With 100% or maximum resistance than synchronous speed in order to
when the motor is started at zero produce a driving torque. Slip is a
speed, the initial inrush line current
reduction of speed with increased Synchronous Motors

load. Synchronous motors, like induction
The amount of slip varies with motors, demand large skVA when
motor design. A slip of starting.
approximately 3% at full-load is Typically, synchronous motors are
common with an induction motor. practical only in sizes above 40
Slip is the difference between the horsepower in which heavy loads
speed of the rotor and the speed of are in constant operation.
the stator rotating magnetic field. Synchronous motors maintain
The equation used to calculate constant speed, synchronized with
percentage of slip at full-load is: power line frequency.
Slip at Full Synchronous Speed – Full Load Speed Synchronous motors have two
=
Load (%) Synchronous Speed features that distinguish them from
induction motors.
Synchronous speed is established • Synchronous motors run at
by the supply frequency and exactly synchronous speed.
configuration of the stator winding • The rotor of a synchronous
into a number of magnetic poles. motor is separately excited
In general, as the load of an with DC while running at
induction motor increases, its speed synchronous speed; this
decreases below synchronous allows operating power factor
speed. to be varied.
Example Characteristics of synchronous
A six pole induction motor runs at motors vary from motor to motor.
almost 1200 r/min at no load and This variability requires that
1140 r/min at full-load when performance characteristics be
supplied with power from a 60 Hz 3- obtained from the motor
phase line. What is the percent slip manufacturer as this information
at full-load? may not appear on the nameplate.
Solution Note: A variation of the induction
Slip at Full Synchronous Speed – Full Load Speed motor, known as the synchronous
=
Load (%) Synchronous Speed reluctance motor, is available for
applications such as synchronized
Synchronous 120(f) 120(60) conveyor systems. These motors run
= = = 1200 rpm
Speed # Poles 6 without slip at exactly synchronous
speed, regardless of load, but should
1200 – 1140
= 5% Slip
not be confused with true
1200 synchronous motors. Power factor is
not adjustable and is, in fact, poorer
than for standard induction motors,
locked rotor and full load currents
are also higher than for standard
squirrel cage motors. Modern Solution

synchronous reluctance motors 1. Find the current drawn from
require no external source of de- each of the lines by the three-
excitation. They are offered in phase load.
numerous versions, including gear 3 V x I x pf
P=
motor styles. 1000
DC Motors
DC motors are used in applications P x 1000 50 x1000
I= = = 167 amperes
3 V x pf 1.73 x 216 x 0.8
requiring speed control, heavy load
starting or where other system
elements require a DC power source. 2. Find the coil current capacity
Full load efficiencies vary from 86 to remaining for the single-phase
92%. load.
334 – 167 = 167 amperes
DC motors have no power factor;
however, when driven through a 3. Find the single-phase power
silicon controlled rectifier (SCR) by available.
an AC generator, the AC does have V x I x pf 125 x 167 x 0.9
P= = = 18.8 kW
a power factor. Use the following 1000 1000
formula to determine DC loads on an
AC generator: When DC motors are at maximum
DC kW x1000 rpm, the system power factor is also
DC amps= AC amps = DC amps x 0.816
DC volts maximized.
According to the application
AC volts x AC amps x 1.732
AC kVA =
1000
requirements, motors can be
designed to provide various speed
DC kW and torque characteristics. Modern
Power Factor = applications will usually involve the
AC kVA
use of packaged static component
Example drive controls, commonly called SCR
Find the amount of single-phase drives. SCR drives are discussed in
power which can be safely drawn detail later in this section.
from a three-phase, 125/216 volt, A major consideration when sizing
four-wire generator set, rated to a generator is to look at the
deliver 100 kW at 0.8 pf. The coil provision or inclusion of a suitable
current rating of the generator set is DC supply. There must be enough
334 amperes. Assume the single- kVA to power both the DC supply
phase load is connected from one and the load.
line-to-neutral and has an operating Single-phase Motors
power factor of 0.9 lagging. In Single-phase motors are common
addition, assume that the generator in fractional horsepower sizes. They
set is supplying a three-phase load may occasionally be used in sizes as
of 50 kW at a 0.8 pf. high as ten horsepower. Single-
phase motors do not have the single-phase motors and have the
benefit of rotating magnetic fields advantage of having a simple
produced by spaced voltage cycles designed rotating magnetic field that
of a three-phase circuit. Therefore, a turns the rotor for starting. In a
separate starter winding is included three-phase motor, there are three
in the stator with provisions to equally spaced voltage cycles
supply a magnetic field that is out of feeding respective windings in the
phase with the main stator winding stator. A rotating magnetic field is
field. This results in a rotating field produced which the rotor
to start things moving. A centrifugal immediately begins to follow.
switch disconnects the starter Therefore, no special starter winding
winding as it achieves rated speed. is required to begin rotation.
Single-phase motors are not
Motor Performance
generally of great concern when
Most three-phase motors are
started by a generator which is
squirrel cage type as mentioned
relatively larger in size. It is good
earlier. When rotor slot cross
practice to divide multiple single-
sections are changed, different
phase motor loads into equal blocks
torque and speed characteristics
per phase. If blocks of single-phase
result. How a motor and its load
motors are spread equally over the
impact a generator is highly
three-phases and started as a group,
dependent on the characteristics of
this motor load can be considered as
the motor.
a single three-phase motor of equal
hp. The skVA may be higher Design Class
because the skVA per hp is typically Motors with various rotor designs
higher for single-phase motors. The are classified in the U.S. by the
total kW load may also be slightly National Electrical Manufacturers
higher because small motors are Association (NEMA) as Design A, B,
frequently less efficient than large C or D. Figure 25 shows a typical
motors. motor nameplate.
If the single-phase motor load
cannot be distributed, it may be
necessary to verify the ability of the
generator to provide the skVA.
Generally, with large blocks of
single-phase motors started from
one phase, the available skVA of the
generator will be 56% of the normal Figure 25
three-phase skVA.
In the following design
Three-Phase Motors descriptions, “slip” applies to the
Three-phase motors are very difference between motor full load
common in industry. They provide speed and its synchronous speed
more output for physical size than Note that these descriptions do not
include synchronous reluctance Design C

motors. Design C motors have high starting
For example, a four pole 60 Hz torque, low starting current and low
motor has a synchronous speed of slip. The high breakaway torque
1200 rpm, actual full load speed makes the Design C a good choice
might be 1164 rpm, in which case for hard-to-start loads.
the slip would be 3%. Each motor These motors are designed to start
design has its own unique at full load torque and run at slips of
characteristics. less than 0.05 at full load. Class C
Design A motors have higher starting torque
per ampere of starting current than
Design A motors are quite
class “B” motors.
comparable to Design B motors,
having normal torque, slip and Design D
starting current. The most significant Design D motors have very high
difference is that starting currents starting torque, high slip and
are limited by NEMA for Design B relatively low starting current.
and not for Design A. Design D permits high breakaway
Design A motors have low rotor torque and high running horsepower
resistance and operate with small to be concentrated in a relatively
slip at full load. A disadvantage of small frame size.
this design is the low starting torque These motors are applicable when
and high starting current. Because “soft” speed is required. Intermittent
they achieve full speed rapidly and drives requiring high acceleration
do not overheat during starting, under high-impact loads would use a
these machines are suitable for Class D motor. The breakdown
applications in which they are torque of a Class D motor runs at a
required to start with very low load slip of 0.5 or higher. This makes a
torque. Class D motor very inefficient. Also,
Design B to keep the starting current low,
The Design B motor is rotor bars of high heat resistant
overwhelmingly the general-purpose material are used. The losses of the
motor of industry. Its combination of rotor circuit necessitate building a
low starting current and normal large and therefore expensive
torque and slip makes it an excellent machine for the given power. This
choice for driving many types of strategy has to be weighed against
industrial loads. the advantage of the soft speed
characteristic which is needed in
Design B motors run at a slip of some applications to determine if a
less than 0.05 at full load with larger Class D motor should be used.
machines running a very efficient
0.005. These motors are applicable Characteristics of each design are
for systems requiring low or medium shown on the speed and torque
torque. characteristic curves, in Figure 26.
designer in selection of a motor for a

specific application. The design class
of a motor is not normally
considered when sizing a genset
because of the greater importance of
the starting kVA requirement.
Starting kVA usually dictates the
size and selection of a generator set
which will provide more than
adequate power for the motor to
produce the required starting torque.
However, the use of oversized
generators, reduced voltage motor
Figure 26 starting and heavily loaded motors
may require special consideration.
Table 13 presents general Motor Starting
guidelines for selecting a motor of A motor’s starting characteristics
the proper NEMA design letter. have a major impact on system
Desired or
Typical
Recommended response to a motor start; this
Required NEMA Design
Conditions
Applications
Letter
greatly influences the final package
Load requires only Centrifugal pumps B or A selection. When a motor is started,
normal starting
torque; continuous
and compressors,
reciprocating
it draws approximately six times its
duty capability with compressors started full load current. This current
ability to handle
minor temporary
unloaded, fans with
normal inertia,
remains high until the motor reaches
overloads palletizers, about 80% of speed. This high
conveyors, lathes,
milling machines,
inrush of current causes a voltage
saws, grinders, dip in the generator. A motor
sanders, drill presses
Hard-to-start loads in Reciprocating com- C
produces mechanical torque that is
continuous or pressors started proportional to the applied voltage.
intermittent service; loaded, conveyors
some overload started under heavy
In cases where generator voltage
capability required load, Banbury mixers, dips below rated voltage, the motor
crushers without
flywheels, hammer
is producing less than proportional
and ball mills, high- torque.
inertia fans
High breakaway Cranes, hoists, D The initial voltage dip associated
torque required; elevators, crushers
intermittent or and punch presses
with motor starting is primarily a
reversing/plugging with flywheels, large- function of the generator magnetic
service; high-inertia diameter fans,
loads with long reversing-type
circuit. Use of a permanent magnet
acceleration time; machine tools excitor or other excitation support
heavy fluctuating
loads
systems will assist in preventing
total excitation collapse in extreme
Table 13
voltage dip cases. It is important for
Of these characteristics, torque is the generator to restore voltage after
most important to the original initial voltage dip to accelerate the
motor to rated speed. The degree of starting kVA capacity to limit

motor loading affects recovery time. momentary voltage drop. A 30%
voltage dip is generally acceptable,
depending on equipment already on-
line. Motor starting capability data is
available on specification sheets and
TMI for all Caterpillar generator sets.
NEMA identifies motors in the U.S.
with a code letter on the nameplate
to indicate starting characteristics.
Table 14 shows the NEMA code and
the starting skVA per horsepower.
Figure 27
Table 15 can serve as a guideline for
motors outside the U.S.
Although unloaded motors impose
high inrush current (skVA) in
generators while starting, kW load Identifying Code Letters on AC Motors
on the engine is usually small. NEMA Code Letter Starting skVA/hp
However, motors can draw more A 0.00 - 3.14
than rated kW during starting and B 3.15 - 3.54
acceleration to rated speed. Motors C 3.55 - 3.99
connected directly to high inertia D 4.00 - 4.49
centrifugal devices or loaded E 4.50 - 4.99
reciprocating compressors cause F 5.00 - 5.59
severe frequency excursions and G 5.60 - 6.29
lengthy motor run up. Comparing H 6.30 - 7.09
starting currents between loaded J 7.10 - 7.99
and unloaded motors shows the K 8.00 - 8.99
extended time loaded motors L 9.00 - 9.99
demand high current; refer to Figure M 10.00 - 11.19
27. The effect of loaded motors on N 11.20 - 12.49
both engine and generator must be P 12.50 - 13.99
determined; particularly if large R 14.00 - 15.99
motors, such as large centrifugal
S 16.00 - 17.99
fans and pumps, have high inertia
T 18.00 - 19.99
loads and increase load during
U 20.00 - 22.39
acceleration.
V 22.40 -
An accurately sized genset will
Table 14
support the high starting kVA (skVA)
requirements of the motor and
supply sufficient output voltage for
the motor so it can develop
adequate load to rated speed. The
generator set must have sufficient
Table 15 lists standard sizes for 50 determined or the loads will

Hz motors. The starting kVA accelerate slowly or even fail to
numbers should be used as a reach full speed.
guideline only. For the exact skVA of Starting Power Factor
a motor, consult the motor Generator sets are typically
manufacturer.
evaluated on the basis of their ability
to start electric motors and
Motor Size kW Starting kVA accelerate to full speed. Regardless
.37 N/A of whether the motor has load or
.55 4.9 not, starting it requires kVA far in
.75 6.9 excess of the motor’s normal
1.1 9.5 running kVA demand. Generator
1.5 13.4 heating is produced by the current
2.2 19.8 which is why generators are rated
3 29.7 for maximum kVA and not maximum
4 41.4 kW. The ratio of kW/kVA is the
5.5 53.8 power factor. Motors exhibit low
7.5 73.1 power factors when starting. Normal
11 103
industrial loads have a power factor
15 143
of 0.8. This is the value used for
18.5 171
NEMA standard and Caterpillar
22 204
ratings.
30 254 Load imposed on the engine during
37 322 a motor start is calculated by:
45 378 kW = Starting kVA x Starting pf
55 502
75 721
90 906
Figure 28 shows the approximate
starting power factor of squirrel
110 1049
cage motors.
132 1255
160 1557
200 1940
250 2476
315 3113
356 3421
Table 15
The rated hp and as starting kVA

must be known to properly evaluate Figure 28
the impact starting a motor will have
upon a specific system. When sizing As shown, a 5 hp squirrel cage
a genset, the acceptable level of motor has a lagging power factor of
motor torque for starting must be approximately 0.6 pf while a 200 hp
squirrel cage motor has a lagging 6.0 kVA x 200 hp = 1,200 skVA
power factor of approximately 0.25 Next, use Figure 28 to find the
pf. lagging starting power factor for a
Figure 28 can be used to help 20 hp motor; it is approximately
determine the total kW needed when 0.46 pf.
a squirrel cage motor, or group of skVA x Starting pf = kW
motors, is started.
1,200 x 0.46 = 552 kW
Example
How much kW is needed when a
Code G 200 hp squirrel cage motor, It was determined in a previous
at 6.0 kVA per hp, is started? example that a 200 hp motor
required 300 kW. Therefore, ten 20
Solution hp squirrel cage motors require 84
skVA = kVA/hp x hp percent more kW than the 200 hp
6.0 x 200 hp = 1,200 squirrel cage motor during starting.
(300 kW vs. 552 kW)
Use Figure 28 to find the lagging Motor Starting Load
power factor of a 200 hp squirrel The nameplate of a motor provides
cage motor; the chart indicates 0.25 important information in regard to
pf. sizing.
skVA x Starting pf = kW The Motor Starting Codes identify
1200 skVA x 0.25 = 300 kW the starting kVA (skVA) per hp. If
the nameplate does not list the
motor starting code, it is likely to list
The chart in Figure 28 can also be the Locked Rotor Amps (LRA). The
used to compare how much kW is LRA is a measurement of the initial
required for one motor versus a inrush of current when a motor is
group of motors. started.
Example Motors, either loaded or unloaded,
How much power is needed when draw several times rated full load
ten Code G squirrel cage motors current when starting. Satisfying
rated at 20 hp each are started? this inrush, places a large
Which requires more power — ten momentary kVA demand on the
20 hp motors, or one 200 hp motor? generator called the starting kVA
The motors are rated at 6.0 kVA per (skVA). SkVA can be calculated
hp each. from locked rotor current.
Solution skVA = (V x LRA x 1.732)/1000
First, find the total horsepower by
multiplying the number of motors by Motors generally exhibit low
the hp of each motor. Use the total starting power factors (0.2 to 0.5)
hp (200) in the following equation: when starting. Load imposed on the
skVA = kVA/hp x hp
engine during starting is calculated required to initially breakaway or

by: overcome friction to start the load
kW = Starting kVA x Starting pf from a standstill. Shown in Figure
29 is the relationship between
starting current and torque. The
Example starting current starts at the locked-
By using the following equation rotor value as determined by the
and the NEMA Code Chart in Table NEMA code or locked rotor amps on
14, the skVA/hp can be determined. the nameplate. The current then
skVA = (skVA/hp) x hp drops to its rated value as speed and
torque approaches normal.
Motor Torque Sample

Motor torque is required to Motor Torque & Current vs. Speed
accelerate and drive the load. Torque
is a turning force. It defines the
ability of the motor to twist the
motor shaft.
Motor loads are established to
determine if generator and engine
have, respectively, adequate kVA
and kW. Motor load is defined as the
torque required by load. This torque,
expressed in N•m (lb-ft), is usually
related to speed. Motor load, in
horsepower can be expressed in the
following equations.
N•m x rpm
hp = Figure 29
7350
Breakaway torque depends on the

lb-ft
hp =
5250 load’s static resistance to rotation.
The load’s static friction can be
higher than the rolling friction
The following torque requirements
depending on the characteristics of
must be established (usually
the driven device. The load
expressed as percent of running
breakaway torque must be less than
torque): Breakaway torque,
motor locked-rotor torque or the load
accelerating torque, synchronous
cannot be started.
torque and peak torque.
Shown in Figure 30 are types of
Starting (Breakaway) Torque torque and the names used for each.
Starting torque is the maximum Also shown is a typical load torque
torque required to start rotation. curve.
Stated differently, it is the torque
to the slip required to produce

torque. If the actual running
torque demanded by the load
is less than rated full load
torque of the motor, running
speed will more nearly
approach synchronous speed.
• Breakaway torque: The torque
required to initially breakaway
or overcome friction to start
the load from a standstill. The
Figure 30 load breakaway torque must
be less than motor locked-
• Locked-rotor torque (also rotor torque or the load
known as Starting Torque): cannot be started.
The torque a motor exerts at
zero speed. The locked-rotor
torque must be greater than
the mechanical breakaway
torque to allow the shaft to
rotate (to start the motor).
Refer to Figure 31.
• Pull-up torque: The minimum
torque produced between zero
and rated speed. In most
cases, this is equal to the
locked-rotor torque but in
some motors may be less than
the starting torque.
• Breakdown torque: The
maximum torque exerted Figure 31
between zero and rated
speed. This point is often the
highest generator load point
and must be considered when
sizing large motors.
• Full-load torque: The torque
capability of the motor at
rated load and speed. Note
that speed is less than
synchronous speed for an
induction motor. This is due
motor life. Figure 33 reflects typical

motor capabilities.
Acceleration Time
The difference between the torque
developed by the motor and the
torque required by the load will
determine the rate of acceleration or
acceleration time. If the load torque
exceeds the motor torque at any
point, the motor will stall.
Considerable heat can be
developed within the motor during
startup, especially in the rotor. The
motor can be damaged from
Figure 32 excessive heat if the starting time is
excessive or exceeds the time
Figure 32 represents speed torque intended by the motor manufacturer.
curves of typical squirrel cage There is no precise limit for the
motors. amount of time allowed to avoid
Acceleration Torque motor damage during acceleration.
Acceleration torque is the net However, motor manufacturers
difference, at any speed, between provide general guidelines. A motor
load required torque and motor start time greater than ten seconds
available torque. Minimum motor may be of concern depending upon
torque must exceed maximum the motor design and manufacturer.
torque demanded by the connected Some motors are protected with
load. The time necessary to achieve thermal overload relays to trip off
full rated speed is of utmost before this becomes a problem. The
importance. Small accelerating number of starts and time interval
torque is usually caused by reduced between starts, as well as the frame
voltage at the motor. size, are items to consider.
Prolonged accelerating time with
high current draw will reduce useful
Figure 33
Estimated Acceleration Time T= Acceleration torque (lb.

Formula ft.)
The formula used to calculate AT = Acceleration Time in
acceleration time is: seconds
Wk2 x ∆N In this example, change in speed is
AT =
308T from zero to full rated speed. To find
T, it is necessary to find the motor
Where: torque average. A simple estimate
may be found by measuring the
Wk2 = Total motor and load
length of several lines running
inertia (lb. ft2) Wk2 +
between motor torque and load
Motor Wk2
torque as provided by motor
∆N = Change of speed (rpm) manufacturer’s torque curves, such
as the one shown in Figure 34. thus preventing the motor from
Then, divide the number by the total starting.
number of lines on the chart. Low voltage operation can cause
overheating, extended load
acceleration times, opening of circuit
breakers and engine/generator
protection shutdowns. Table 16
shows the minimum recommended
motor ratings.
Minimum Recommended Motor Ratings
Induction Synchronous
Volts RPM
Motors hp Motors hp
601-3,000 3,600 250 —
601-3,000 1,800 or less 250 250
3,001-5,000 3,600 350 —
3,001-5,000 1,800 or less 300 250
5,001-7,000 3,600 1,000 —
Figure 34 5,001-7,000 1,800 or less 800 600
Table 16
Synchronous Torque
The steady-state torque developed Inrush current to the motor causes
by a synchronous motor at rated a rapid drop of generator output
speed. voltage. In most cases, 30% voltage
Peak Torque dip is acceptable, depending on
Maximum torque a load requires equipment already on-line. Degree of
from its driving motor. dip must be identified by an
oscilloscope. Meters or mechanical
Motor Voltage recorders are too slow for this
A properly sized genset must have measurement.
adequate kW (power) and kVA
capability to satisfy the demands of Single-speed, three-phase,
a motor during starting. constant-speed induction motors,
when measured with rated source
Most motors are energized with voltage and frequency impressed
electrically operated contactors. and with rotor locked, must not
Extremes in voltage dip due to motor exceed the values listed in Table 17.
starting may cause the
electromagnetically held contactors
to dropout or close intermittently
Locked Rotor Current — NEMA MG 1
60 Hz - 230 Volts 50 Hz - 380 Volts

Horsepower Locked Rotor Design Letters Horsepower Locked Rotor Design Letters
Current, Amperes* Current, Amperes **
0.5 20 B,D,E 1 or less 20 B,D,E

0.75 25 B,D,E 1.5 27 B,D,E
1 30 B,D,E 2 34 B,D,E
1.5 40 B,D,E 3 43 B,C,D,E
2 50 B,D,E 5 61 B,C,D,E
3 64 B,C,D,E 7.5 84 B,C,D,E
5 92 B,C,D,E 10 107 B,C,D,E
7.5 127 B,C,D,E 15 154 B,C,D,E
10 162 B,C,D,E 20 194 B,C,D,E
15 232 B,C,D,E 25 243 B,C,D,E
20 290 B,C,D,E 30 289 B,C,D,E
25 365 B,C,D,E 40 387 B,C,D,E
30 435 B,C,D,E 50 482 B,C,D,E
40 580 B,C,D,E 60 578 B,C,D,E
50 725 B,C,D,E 75 722 B,C,D,E
60 870 B,C,D,E 100 965 B,C,D,E
75 1085 B,C,D,E 125 1207 B,C,D,E
100 1450 B,C,D,E 150 1441 B,C,D,E
125 1815 B,C,D,E 200 1927 B,C,E
150 2170 B,C,D,E
200 2900 B,C,E
250 3650 B,E
300 4400 B,E
*Locked rotor current of motors designed for voltages other than 230 volts shall be inversely proportional to the voltages.
**The locked rotor current of motors designed for voltages other than 380 volts shall be inversely proportional to the voltages.
Table 17
line, as shown in Figure 35. Full

Motor Starting Techniques
voltage starting is the most widely
There are various methods used to
used motor starting method.
start motors. Those that will be
discussed are full voltage, soft Full voltage starting uses a
starting and reduced voltage. momentary push button as the start
switch. When pushed, the button
Full Voltage Starting energizes contact coil “M”, as
The least complicated motor shown in Figure 35. Then the motor
starting method is full voltage contacts, “M”, close to start the
starting or across-the-line starting. motor; a seal in contact “M” holds
Motors are simply connected to the the contacts in until the “stop”
power source by switches in the
button is opened. The on-off control The generator set must have
commonly features integral overload sufficient motor starting kVA
protection. capacity to limit voltage drop. If
Full line voltage is supplied to the actual values of the motor starting
motor instantly when the motor current cannot be determined, an
switch is actuated; refer to Table approximate value of 600% of full-
18. Maximum starting torque is load rated current is a good
available; therefore, the motor will approximation for Design B motors;
have minimum acceleration time. approximate 1500% of full-load
Reduction of acceleration time is rated current for Design E motors.
advantageous for motors that cycle Refer to Figure 36.
off and on frequently. The shorter Full voltage starting is used unless
the time it takes the motor to get to there are limitations on inrush
full speed, the less heating will occur currents. Most public utilities do not
on the motor windings. This will allow full voltage starting of large
allow for increased service life of the motors. When large motors are
motor. started, a relief must be provided.
Figure 35
Reduced Voltage Starters

Line Current Starting Torque
Motor Voltage
Type of Starter % Full Voltage % of Full Voltage
% Line Voltage
Starting Current Starting Torque
Full Voltage Starter 100 100 100
Autotransformer
80% Tap 80 *68 64
65% Tap 65 *46 42
50% Tap 50 *29 25
Resistor Starter
Single Step (Adjusted
80 80 64
for motor voltage to be
80% of line voltage)
Reactor
5
50% Tap 50 50
20
45% Tap 45 45
14
37.5% Tap 37.5 37.5
Part Winding
(Low speed motors only)
75% Winding 100 75 75
50% Winding 100 50 50
Star Delta 57 33 33
Solid State Adjustable
* % line current is 64%, 42% and 24% before addition of autotransformer magnetizing current.
Advantages Disadvantages
Autotransformer
1. Provides highest torque per amp of line current. 1. In lower hp ratings, it is most expensive design
2. Taps on autotransformer permit adjustment of starting
voltage.
3. Closed transition starting.
4. While starting, motor current is greater than line current.
5. Low power factor.
Resistor
1. Smooth acceleration — motor voltage increases with 1. Low torque efficiency
speed. 2. Resistor heat
2. Closed transition starting. 3. High power factor during start.
3. Less expensive than autotransformer starter in lower hp
ratings.
4. Available with several accelerating points.
Part Winding
1. Least expensive reduced voltage starter. 1. Requires special motor design for voltages higher than
2. Closed transition starting. 230 v.
3. Most dual voltage motors can be started part winding on
lower of two voltages.
4. Small size.
Start Delta
1. Moderate cost — less than resistor or autotransformer. 1. Requires special motor design.
2. Suitable for high inertia, long acceleration loads. 2. Starting torque is low.
3. High torque efficiency.
Table 18
• Selecting a motor with

inherent soft-start
characteristics.
• Interposing controls between
the motor and power source
to modify motor torque.
Reduced Voltage Starting
Reduced voltage starting reduces
the skVA demand on a generator set
Figure 36 for motor starting. There is also a
reduction in motor starting torque.
Soft Starting — Cushioning Motor Though a voltage dip can often
Starting Under Load cause problems, a controlled voltage
Motors may be soft-started dip can be beneficial. Reducing
(started with decreased load or at motor starting kVA can reduce the
reduced torque) to bring the load up required size of the genset, reduce
to speed gradually or to minimize the voltage dip, and provide a softer
starting currents. Motors may be start for the motor loads. However,
over stressed when developing the time to reach full operating speed
torque necessary to start and increases. Figure 37 shows the
accelerate a large or high inertia effect of reduced voltage on torque.
load. Also, a high starting current
may strain the electrical supply
system beyond its capability to
provide current to the starting motor
or other connected loads.
Three options for soft-starting
motors include:
• Installing a coupling to the
shaft of the motor. Doing so
allows the motor to reach full
speed before the load does.
Most common would be an
eddy-current clutch, magnetic
coupling, or variable-pitch
sheave drive. This technique
does relieve the generator set
engine of some horsepower
Figure 37
demand while starting, but
does not relieve the generator Any reduction in voltage during
of initial skVA demand. starting sequence will have effect on
both torque and load acceleration.
Starting torque varies directly with Reduced voltage during start can
the square of the voltage impressed give relief from excessive current
on the stator. If the voltage imposed inrush demand and excessive
on the terminals of an induction transient disturbances. However, the
motor being started is reduced from motor may not have sufficient
its rated voltage to some given torque to accelerate to rated speed,
percentage of this full value, the especially if the motor is required to
power demand of the motor will be accelerate a connected load with a
reduced to a value equivalent to the heavy inertial content.
full voltage start kVA times the Starting current varies directly with
percent of full voltage squared. the impressed voltage.
% decrease of rated volts = x
Example
x2 = Available Torque What is the current draw of a 230
V motor that is reduced to 200 V?
Using Ohm’s Law, it is seen that Solution
the power consumed in the circuit 200
= 0.87
will vary directly as the square of 230
the current flow. Therefore, since
current flow in a given circuit is Current draw is 87% of rated.
directly proportional to the voltage Figure 38 illustrates the effect of
across the circuit, the result of reduced voltage on current.
reducing the voltage to some
percent of full voltage will be a
reduction in power consumed in the
circuit equal to the percent of full
voltage squared.
Example
If line voltage of 230 V is supplied
to a 230 V motor, the available
torque is 100%. If a 230 V motor is
reduced to 200 volts, what is
available torque?
Solution
% decrease of rated volts = x
x2 = Available Torque
Figure 38
200
=x There are several types of reduced
230
motor starting.
x2 = 0.756 = Available Torque
• Autotransformer-Open
The available torque is 75.6%. Transition
• Autotransformer-Closed autotransformer starter provides

Transition higher torque per ampere of line
• Reactor current than other types of reduced
voltage starters. Actual line current
• Resistor will be a few percent more than the
• Part Winding 64% in the example because the
• Star Delta autotransformer requires
approximately 25 kVA per 100
• Solid State
motor horsepower for magnetizing
All these reduced voltage starting current.
techniques decrease motor starting
The transition to full voltage is
torque. Decreased motor starting
usually determined by a timer.
torque detracts from the motor’s
However, in some cases it may be
ability to start and achieve rated
done manually. The simplest
speed when burdened by a load. If
arrangement is open circuit transfer
reduced voltage starters are used,
from reduced to full voltage, but it
the reduction in starting torque
causes severe electrical and
developed by the motor must be
mechanical disturbances during the
considered.
transition switch.
Reduced Starting Methods Figure 39 shows a circuit drawing
Autotransformer — Open Transition and torque chart of an
Autotransformer starters, also Autotransformer – Open
called auto compensators, reduce arrangement.
voltage to the motor terminals for
starting by transformer action. They
are available for very large high and
low voltage motors. The
autotransformer has a reduced
voltage winding tap which is
removed from the circuit and
connected directly to the line as the
motor approaches rated speed.
Autotransformer starters typically
have three taps available to select
50%, 65% or 80% of line voltage.
With transformer action, current
drawn from the source will vary as
the square of voltage at the motor
terminals. When the 80% tap is
used, the line current will be 80%
squared or 64% of line current that
would be drawn at full voltage. With
the transformer action, the
seconds. It is the most expensive of

Autotransformer – Open all starters.
Current drawn from the line will
vary as the square of voltage at
motor terminals; when the motor is
connected to the third (80%) tap,
line current will be 80% squared, or
64% of line current that would be
drawn at full voltage. The starter
requires approximately 25 kVA per
100 motor horsepower as
magnetizing current. This is added to
the starting kVA of the motor being
started.
Figure 40 shows a circuit drawing
and torque chart of an
Autotransformer – Closed
arrangement.
Autotransformer – Closed
Figure 39
Autotransformer — Closed
Transition
An alternative to open transition
switching, is closed transition.
This technique minimizes shock by
providing continuous flow of current
while switching from
autotransformer tap to full voltage.
Closed transition switching, though
involving slightly more complex
switching, is preferred for
autotransformer starting.
Autotransformer starters are
magnetically controlled. Three taps
on the transformer secondary are set
for 50%, 65%, and 80% of full line
voltage. These three contactors, a Figure 40
timer, and a transformer make up
the starting device. This starter is
very smooth in acceleration and
allowance starting time is 30
Reactor — Resistor sample Reactor/Resistor

Reactor starters reduce voltage to arrangements.
the motor by inserting resistance or
reactance into each leg of the circuit Reactor
and then short out when the motor
approaches operating speed. This
type of starter uses two contactors,
a timer, and a reactor or resistor as
the starting device.
Allowable starting time is five
seconds. It is the least flexible in
application of all starting devices but
smooth in acceleration and priced in
the middle of all starters.
The added resistance acts as a
voltage dropping device. It adds a
loss to the circuit and imposes load
on the engine. This method provides
smooth acceleration as the starting
circuit is removed without
momentarily disconnecting motor
from line. (The line current equals Figure 41
motor current, resulting in a lower
“torque to source” kVA ratio for Resistor
starting than with autotransformers.)
For example, with 80% voltage
applied to the motor terminals, the
motor current will be 80% of normal
full voltage current and likewise
80% current will be required from
the line. Contrast this to 64% line
current with an 80% tap
autotransformer.
Reactor starting uses two
contactors, a timer, and a reactor as
the starting device. Allowable
starting time is 15 seconds. Series
reactor starting is usually used on
large motors. Its application
flexibility is limited to only the high
voltages and currents.
Figure 41 and Figure 42 show
circuit drawings and torque charts of Figure 42
Part Winding ratio, it does not allow for a smooth

A special motor with two parallel start and is not suitable for small,
stator windings is required for part high speed motors. Acceleration
winding starting. These are time is between 5 and 15 seconds
successively connected to the line depending on the type of motor
as motor speed increases. used.
Part Winding and torque chart of sample Part
Winding arrangement.
Wye (Star) — Delta SCR Gates
Wye-delta starting requires that the
motor being started have all six or
twelve leads brought out to the
connection box. The motor starts as
a wye (star) connected motor and is
then switched to run as a delta
connected motor.
When connected wye, voltage
impressed on each individual
winding is 58% of full value of delta
connection. Starting torque and
current are 33% of across-the-line
value. This type of starter has the
longest allowable acceleration time
of 45 to 60 seconds. When wye-
Figure 43 delta is used with a limited capacity
generator set, the additional loss in
Full line starting is applied to a part the motor’s starting torque due to a
of the motor’s winding. Current and significant transient voltage dip
developed torque are reduced to that usually results in the motor failing to
of one winding while starting. accelerate to near rated speed prior
Torque characteristics are better if to making transition to running
the stator is designed for part mode. The power source is started
winding starting but standard dual almost as if it was started directly
voltage are sometimes used. Two across the line, and therefore fails.
contactors and a timer are the parts Note: Alternators powering motors
of this starter. However, an equipped with delta starters should
additional cost of the motor itself be sized as if the motors were being
has to be taken into consideration started directly across-the-line.
since it may be up to 50% more
expensive than a standard squirrel
and torque chart of sample Wye
cage motor. Although this technique
(Star) arrangement.
can produce a good torque to kVA
Wye (Star) only active during starting and

therefore do not require additional
generator capability to accommodate
voltage distortion due to the SCR’s.
If the solid-state motor starter does
not have an automatic bypass, the
SCR’s voltage distortion will have to
be compensated by oversizing the
generator. A guideline in this
oversizing is to use two times the
kW load. Refer to the Harmonic
Content Section for more
information.
and torque chart of a sample Solid
State arrangement.
Solid State
Figure 44
Solid-State Starter
Solid-state starters offer many
options in achieving desired starting
characteristics. Solid-state starters
adjust torque, acceleration ramp
time and current limit to cause a
motor start which has a controlled
acceleration. Solid-state starters
offer smooth, step-less motor
starting by varying the conduction
angle of SCR’s. The conduction
angle varies from 20 to 100% which
in turn controls the motor voltage
from 40 to 80%. They have the
advantage of operating without Figure 45
mechanical parts and large electrical
switching contacts. This provides a The user adjusts the control to
very smooth application of power. deliver the best starting
The solid-state starter is not to be characteristic for the application.
confused with the solid-state Variations of current and voltage
adjustable speed drive. With a solid- limit are sometimes used to achieve
state starter, circuits are typically linear speed ramp, however the
operating principle of the controlled

parameter is always based on Current Ramp
voltage control.
Voltage Ramp
Voltage/time ramp increases
voltage until full voltage is applied to
the motor terminals. Constant kVA
is maintained, and sudden torque
changes are eliminated, as illustrated
in Figure 46. Initial voltage step,
acceleration ramp, and current limit Figure 47
are usually adjustable. An extended
acceleration ramp time and low
current limit setting results in the Table 18 lists the various methods
least voltage and frequency dips. and types of starting, and their
principle effects on motor starting.
Voltage Ramp
Extreme care should be given
when applying reduced voltage
starting to engine gensets. The
amount of available starting torque
is reduced. Any transient voltage dip
during start will further reduce the
starting torque. For example, if a
motor is being started with an
autotransformer starter on the 65%
Figure 46 tap, the motor will have only
42.25% of its full voltage starting
Current Ramp torque available upon start. If the
Use of the current limit ramp is system voltage dips 20% during
very common. Current is ramped up transient, the voltage at the motor
within a prescribed time to reach a terminals will be only 80% of 65%
programmed limit; refer to Figure 47. of rated voltage (52% of full
Current limit settings from 150% to voltage). Squaring 52% gives a net
600% of full load current are value of 27% of full voltage starting
typically available. A 300% limit torque, not the anticipated 42.25%.
reduces the starting kVA by 50%
from the normal 600% current with
full voltage across-the-line starting.
Use of the current limit setting
reduces motor torque available to
the load as shown in Figure 45.
are already connected. All loads

Table of Methods and Types of Motor Starting following the initial intermittent load
PU Rated PU Rated (like a furnace) must include the
Method and PU Line
Type of Voltage
Start Start intermittent load as part of its total
Torque kVA as well. By considering this, more
Starting Applied
Available Required
kVA may be needed and a larger
Full Voltage
Across-the-Line 1.0 1.0 1.0 genset may be appropriate.
Full Voltage Part Motor Starting Troubleshooting
Winding (See 1.0 0.70 0.70 Techniques
Notes 1 & 3) If motor starting is a problem,
Reduced Voltage 0.80, 0.64, 0.67, consider the following:
Autotransformer 0.65, 0.42, 0.45,
(See Note 2) 0.50 0.25 0.28 • Change starting sequence.
Reduced Voltage Start largest motors first.
Reactor/Resistor 0.80, 0.64, 0.80, More starting kVA is available,
(See Notes 1 & 0.65 0.42 0.65 although it does not provide
3) better voltage recovery time.
Reduced Voltage
0.58 0.33 0.33 • Use reduced voltage starters.
Star-Delta
This reduces the kVA required
NOTES:
1. Values are typical. Various values of skVA and torque
to start a given motor. If
are available depending upon motor/starter design. starting under load, remember
Consult the motor/starter manufacturer for specific data. this starting method also
2. The calculated percentage values of Start kVA have reduces starting torque.
been increased by three percentage points to allow for
• Use current limiting starters.
the magnetizing kVA required for the autotransformer.
3. Values listed are typical. Consult with the customer or • Specify oversized generators.
the manufacturer of the motor/starter for specific data. • Use wound rotor motors.
4. In the absence of specific data, indicated typical data They require lower starting
may be used for estimating purposes, but should be current, but are more
shown as “assumed values in lieu of specific data”.
Performance of actual equipment may vary from
expensive than other motors.
calculated performance on all calculations and • Provide clutches so motors
quotations. start before loads are applied.
Table 19 While starting kVA demand is
not reduced, time interval of
high kVA demand is
shortened.
Intermittent Starting
When a motor is run intermittently, • Improve system power factor.
the transient response time must be This reduces the generator set
considered. When an intermittent requirement to produce
motor is started, the voltage dip reactive kVA, making more
which occurs must still be in an kVA available for starting.
acceptable range that does not • Unload the motors. Starting
adversely affect other loads which loaded motors can cause very
high generator set loads VFD’s start at zero frequency and

during the motor starting ramp up to a set point. Variable
phase. voltage drives start at zero voltage
and ramp up to a selected point.
Miscellaneous Loads Both are under a current or torque
Most facilities will have both limit to avoid large inrush current. A
lighting and motor loads. Some variation of the variable speed drive
facilities may have additional is the reduced voltage or reduced
miscellaneous loads; these could current starter; see description under
include adjustable speed drives, UPS motor starting.
loads, single-phase loads and
Generally, when these drives
elevator loads.
represent more than 25% of the
Adjustable (Variable) Speed Drives total load on the generator set, it
Electronic adjustable speed drives may require a larger generator.
are used to control the speed of VFD’s require large generators.
both AC and DC motors. Speed VFD’s are current limiting and
control allows application of motors, reduce kW and kVA. Non-linear
at their most efficient speed, to be current is drawn which has
matched to the demand created at a harmonics. This causes a voltage
particular moment. Terms used to drop across the reactance of the
describe these drives include the genset. When Total Harmonic
following. Distortion (THD) exceeds 15%,
• Variable Speed Drive (VSD) additional generator capacity may be
• Variable Frequency Drive needed. Larger generators have
(VFD) greater reduction in impedance of
the generator; this reduces the
• Adjustable Frequency Drive
effects of the harmonic current
(AFD)
distortion.
• Adjustable Speed Drive (ASD)
For six-pulse VFD’s, twice the
These drives rectify incoming AC running kW of the drive is a typical
power to form DC power. The DC is sizing factor used to offset any
used to either power a DC motor reduction in starting kW or kVA. If
directly, or power an inverter that an input filter is used to limit current
converts DC back into AC at a to less than 10%, the sizing factor
desired voltage and frequency for can be reduced down to 1.4 times
driving a motor at any speed at any the running kW of the drive.
point in time.
Passive filters may be used to
The rectification of AC with SCR’s reduce the impact of harmonic
distorts current waveforms and distortion. However, the possible
subsequently causes distorted effects of leading power factor with
voltage waveforms, which can have tuned inductor/capacitor filters at
impact on other equipment start-up or with light loads may
connected to the same source.
effect voltage regulation of self- supplies (UPS). Each of these

excited generators. devices converts the sinusoidal
Silicon Controlled Rectifier (SCR) supply voltage into a direct current
Systems voltage. In some cases, the
SCR drives allow infinite speed equipment may convert the DC
adjustment of electric motors. They voltage back to AC voltage. Used
are used in a variety of applications. with limited power sources, such as
DC motors used in elevators, cranes engine-driven generator sets, SCR
and printing presses utilize SCR’s. switching causes severe voltage and
Additionally, AC variable frequency current waveform distortion at the
drives (VFD) and AC variable voltage power source. Current waveform
input (VVI) drives used in pumps, distortion can develop harmonic
fans, process conveyors, machine resonance in system equipment.
tools and printing presses use This causes heating in motor and
SCR’s. generator coils.
Typically, SCR drives may require The creation of distortion with an

oversized generators. Operating DC SCR device can be shown by looking
motors at variable speeds causes the at a simple generator supplying an
generator Power Factor to vary. SCR controlled load; refer to Figure
48.
Accordingly, AC generators are
oversized to 0.6 or 0.7 PF to provide
more generator ampere capacity.
Testable capacity of the genset is
given by the following equation:
EkW = (bhp – rad fan hp) x Gen eff x 0.746
Additionally, the generator must be Figure 48

form-wound to provide additional
mechanical bracing of the generator Turning the SCR “on” at some
winding. This bracing resists the point during the applied voltage
forces caused by current surges cycle creates an instantaneous
resulting from operation of the SCR demand for a large amount of
controllers. Generator winding current to flow in the circuit. With
temperature rise design limit is also an SCR, current does not flow until
lowered to compensate for the SCR is gated “on”. This current
additional heating caused by the flow results in an instantaneous
SCR load. voltage drop within the internal
Undersized generators may cause impedance or reactance of the
circuit breaker tripping. generator. Consequently, the voltage
at the generator output terminals
SCR systems lend themselves to
appears as a distorted sine wave;
infinite speed control of motors,
refer to Figure 49.
rectifiers and uninterrupted power
power outages. The UPS continually

conditions power and if the normal
power source is not available, the
UPS provides power to the critical
load until the standby power
generation can come on-line. The
generator set should be sized to the
UPS rating, not the load.
Figure 49
Continuity and isolation from
Over time, these distortions which power source disturbances can be
occur on a three-phase power assured by using either a rotary or a
source can cause unfavorable static UPS system.
performance of the entire system. Rotary systems use a motor-
When planning systems with SCR generator set to isolate the critical
devices, the control manufacturer load combined with kinetic inertia
must be informed that a limited storage technique or batteries to
power source (generator set) will be carry the critical load while cranking
used. The system can then be a diesel engine.
designed to minimize distortion Static systems isolate critical load
problems. Limiting SCR loads to through solid-state devices which
66% of a Caterpillar generator’s use batteries to bridge power
prime power rating ensures regulator interruptions until a genset is
control and avoids generator available to power the system.
overheating caused by harmonics. UPS’s can also be used to perform
Applications requiring high load an orderly engine shutdown to
factors must be analyzed on an minimize restart damage.
individual basis.
Static UPS systems use static
Welding Loads components to provide quality
Welders draw erratic fluctuating power to critical equipment,
current. These current fluctuations independent of the quality or
produce voltage waveform distortion availability of the normal power
due to relatively high-load source source. The simplest systems
impedance. Generator sets may consist of a rectifier (converter), a
require significant derating with DC storage battery bank, and an
welder loads. inverter.
Uninterruptible Power Supply (UPS) The rectifier, sometimes called
A UPS system is an assembly of converter, is a device that converts
equipment used with electrical loads AC current to DC current.
sensitive to power source The inverter uses Solid State
disturbances or that require absolute technology to convert DC to a
continuity of power. The UPS can waveform that is then filtered so it is
store energy for a period during
suitable for powering the critical distortion at the source. Refer to the
load. Non-Linear Load Section for
A bank of storage batteries examples.
“floats” on-line to provide seamless In three-phase rectifiers, the
DC power to the inverter in the circuits and circuit elements may be
event of power source loss to the arranged to provide DC power with
rectifier. The batteries get their six or twelve DC current pulses per
restoring charge and standby float AC input cycle.
charge from the rectifier’s DC The higher the number of pulses
output. per cycle, the smoother the demand.
The DC output of the rectifier Therefore, a six-pulse rectifier has a
provides for two functions during more distorting demand than a
the time when an AC power source twelve-pulse rectifier.
is available at its terminals. A six-pulse system should have a
1. It provides regulated DC to the generator rated for continuous duty
inverter for powering the critical at 80°C temperature rise. An
load. upgrade of the voltage regulation
2. It maintains the “state of system may be necessary, as well.
charge” on the bank of DC The subtransient reactance should
batteries; including recharging if also be determined before sizing the
the state of charge has been generator.
depleted by a recent normal For a twelve-pulse system, where
power outage. these loads are more than 25% of
The AC output of the inverter is the generators standby rating, a
“conditioned power” to match the generator rated for continuous duty
voltage and frequency requirements at 105°C rise for Class F and H
of the critical load at all times. insulation systems should be
selected.
During a power interruption, power
for the system comes directly from For a twelve-pulse system where
the reserve battery bank without the loads are less than 25% of the
switching. The load is seen as the generators standby rating, a
static power converter/battery standard generator and automatic
charger. voltage regulation system may be
applied.
Six-Pulse and Twelve-Pulse Rectifier
Size and cost considerations
The rectifier or converter unit,
which converts AC to DC in a UPS dictate the number of pulses to be
system, consists of large individual used in system design. Problems
rectifiers in circuits to control the DC with high THD with a six-pulse
output. They draw current in pulses rectifier can typically be minimized
from the AC source. These current by the rectifier manufacturer using a
properly designed passive filter.
pulses are not sine wave in shape
and cause voltage waveform
By-Pass Capability The UPS must have circuitry to

Some UPS systems include ensure the inverter output and by-
additional components to allow the pass source are synchronized.
capability to by-pass the UPS in the Source voltage and frequency must
event of failure within the system, be within an acceptable range, or
system maintenance or momentary the UPS will disable the automatic
overloads on the critical load side. by-pass feature.
Figure 50 is an example of a UPS The demand for close control of
with by-pass capability. A device voltage and frequency is of more
called a static transfer switch allows concern for by-pass with a generator
automatic and virtually uninterrupted set source. This is because of harsh
transfer of the critical load back to effects on voltage waveform caused
the incoming source in the event of by the UPS rectifier and the
a planned or unplanned system possibility of generator set frequency
event such as mentioned above. deviation due to pulsating load or
small load changes.
UPS with Bypass Capability
Figure 50
An isochronous governor is typically with one or more UPS

recommended on the generator set systems than required to power the
and the UPS should be adjusted or load. Therefore, the critical load can
designed with the widest possible be sustained even with the loss or
window of voltage and frequency failure of any one individual UPS
acceptability for by-pass. system. A static switching bypass,
Parallel Redundant UPS although of lesser importance for
reliability, may still be used for
Extremely critical applications may
maintenance or momentary overload
use a parallel redundant UPS; refer
and fault clearing capability.
to Figure 51. These are multiple UPS
systems operating in parallel,
Parallel Redundant UPS
Figure 51
Static UPS System
Figure 52
UPS Interface load changes are sufficiently

Electrical loads sensitive to power small to avoid speed changes.
disturbances during substation • Isolate critical load through a
switching, voltage fluctuations or motor-generator set to avoid
total outages require absolute five-cycle power interruptions
continuity of power. Continuity can of utility.
be assured by isolating critical loads
Combining the characteristics of a
and incorporating one of the
UPS system, particularly static
following:
systems as shown in Figure 52, and
• Assign a generator set solely a generator set present special
to the critical load. Sudden considerations to ensure
compatibility. An understanding of Generator sets inherently have

how these systems work and difficulty controlling voltage with
interface is essential. leading power factors, and rising
A UPS is rated in output kVA. In voltage may be observed. This
sizing a genset, it is important to condition is emphasized during UPS
recognize the need to provide power start-up by the power walk-in
based on UPS input. For instance, a feature. Typically, a UPS has some
rated UPS 100 kVA requires more means of gradually applying load to
than 100 kVA from the power the source over a 10 to 20 second
source; the difference between input period. An unloaded filter may
and output kVA is the efficiency of present a leading capacitive power
the unit. In addition, battery factor load beyond the generator’s
recharge load might be as high as voltage control capability.
25% of the output rating. Other loads connected to the
UPS systems typically have generator will counter this effect.
electronic circuits that discern input Also, disconnecting the filter at
voltage and frequency change. All lower UPS loads will minimize the
UPS should be designed or adjusted problems.
with operating parameters that are Filters may also act as stored
compatible with the genset. This energy devices affecting circuit
includes using the widest possible switching components such as
window of voltage and frequency automatic transfer switches.
acceptance when used with a Indiscriminate filter designs may also
genset. cause resonant conditions with other
Coordination between the genset circuit elements.
supplier and the UPS supplier is Impact of Other Loads
critical in meeting the client’s needs. Most electrical devices and
Input Filters equipment are relatively unaffected
Filters may interact with other when powered by generator sets
components within a system. with UPS loads. However,
Therefore, they should be considered knowledge of potentially sensitive
very carefully. Typical tuned circuit devices may be of value in system
filters represent some compromise planning. Many electronic devices
when used with rectifiers that are contain internal AC to DC power
exposed to broad power changes, supplies with adequate filtering and
such as may be encountered in UPS are relatively immune to waveform
applications. Filters with capacitive distortion. A few special purpose
reactance components may have electronic or control devices that
little effect on power factor with depend upon source voltage “zero
rated load on the UPS; however, the crossings” for timing may perform
power factor may become capacitive erratically. If these devices are of
leading at a part-load condition. low power, a simple and low cost
filter will usually eliminate any use 0.9 pf (typical for computer
problem. systems).
Power factor correction capacitors Battery recharge kW generally
are used primarily for economic ranges from 0 to 25% of input kW
reasons. They can also be effective (15% is typical). If unknown, use
in reducing waveform distortion. 25% of output kW for an
Caution must be exercised where approximation.
power factor correction capacitors If UPS efficiency is unknown, the
are used. A resonant condition at following guidelines are
one of the harmonic frequencies recommended:
with some part of the line
• Use 0.85 if UPS < 100 kW.
inductance such as a transformer,
on-line motor or the generator is • Use 0.875 if UPS > 100 kW,
possible. Excessive and possibly but < 500 kW.
damaging currents at the harmonic • Use 0.90 if UPS > 500 kW.
frequency can flow through the
Note: Maximum input with
equipment. It may be advisable to
redundant systems is less than total
keep them off line until effects of
rating of individual systems.
operating on an emergency
generator set with non-linear loads Part B
can be observed. Establish the minimum size
generator to contain waveform
UPS Sizing Example
distortion (quality of electric power).
The following is a procedure to use
in sizing Caterpillar generator sets • 6-pulse rectifier/charger:
that have static UPS systems as part Minimum standby rated
or all of their load. This procedure generator set =
has four parts: UPS input kW x 1.6.
Part A • 12-pulse rectifier/charger:

Establish UPS input kW. Use UPS Minimum standby rated
input kW from supplier data. (In this generator set =
example use 255 kW.) If not UPS input kW x 1.4.
available from supplier, the following
procedure and guidelines are
recommended to approximate or
estimate UPS input kW.
UPS Output kW + Battery Recharge kW
UPS Input kW =
UPS Efficiency
UPS output for computer loads is

frequently stated in terms of kVA.
For approximating, if UPS output
kVA is given and kW is unknown,
Part C Loads on the generator set

Size the generator to frequently include large motors for
accommodate other loads. air conditioning and other support
functions. Following selection of the
• 6-pulse rectifier/charger:
generator set in Part D, a check
Minimum standby generator
should be made to determine if the
rating with other loads =
generator set has adequate motor
(UPS input kW x 1.15) + kW
starting skVA capability.
of other loads.
In special cases, it may be possible
• 12-pulse rectifier/charger:
to optimize economics by selection
Minimum standby generator
of a generator with standby rating as
rating with other loads =
determined in Part D and driving
(UPS input kW x 1.10) + kW
with an engine which has a standby
of other loads.
rating commensurate with the actual
Part D total kW load on the generator set.
Compare “B” and “C” for final Actual total kW load is the UPS
selection. Select larger of Part B or input kW plus kW of other loads.
Part C and round to nearest larger
Regenerative Power
size standby generator set.
Some motor applications, such as
Example: hoisting, depend on motors for
Select a standby generator set for braking. If a mechanical load causes
powering a UPS rated 200 kVA/180 the motor to turn faster than
kW. Other loads connected to the synchronous speed, the motor will
generator set total 100 kW. act as a generator and feed power
Solution: back into the system. The term
Part A: From supplier data, the “regenerative power” is sometimes
UPS input is 255 kW. used to describe the power
produced by these loads. If no other
Part B: The rectifier/charger is a 6-
loads are connected to absorb this
pulse circuit, 255 kW. Minimum
energy, these loads will cause the
standby rated generator set = 255
generator to act as a motor, possibly
kW x 1.6 = 408 kW.
causing engine overspeed which can
Part C: Sizing for other loads. lead to engine failure.
Minimum standby generator set
Only engine frictional horsepower
rating with other loads = (255 kW x
can be relied on for braking.
1.15) + 100 kW = 393 kW.
Exceeding frictional horsepower
Part D: Select larger of Part B or causes the generator set overspeed.
Part C. Part B (408 kW) is larger
In calculating the ability of a
than part C (393 kW); therefore, a
system to overcome regenerative
standby generator set of at least
power, it is conservatively
408 kW is recommended. A
recommended that only engine
Caterpillar 450 kW generator set will
friction horsepower be considered.
satisfy this application.
Engine friction horsepower at
synchronous speeds is available but, if voltage fluctuation to highly

from the engine manufacturer. sensitive equipment must be closely
Typically, a generator set will retard controlled, kVA capability of the
approximately 10% of its rating. power source must include starting
When combinations of connected of this low power factor load.
load and engine frictional Typically, a genset can energize a
horsepower are not sufficient to transformer that is two to four times
restrain regenerative energy, load the genset’s kVA rating. A voltage
banks may be added to protect the dip occurs at the generator
genset from being affected terminals, almost as if a short circuit
regeneration. had occurred. However, transformer
flux builds up in a few cycles and
Transformers voltage is restored.
Transformers are used in power
distribution systems for voltage Transformer Efficiency Losses
step-up, voltage step-down, or Power transformers are relatively
circuit isolation purposes. They are efficient. Typical efficiencies are 95
commonly used to step-down to 99% at full load. The efficiency is
transmission line voltage to a the ratio of real power output to
useable distribution system voltage power input. Losses are mainly
and to step-down service or supply losses incident to magnetization at
voltage to the utilization voltage of no-load and the addition of I2R
user equipment. losses caused by the load current.
Transformer Magnetizing Current Transformer Taps

When a transformer is initially Transformer taps can be used to
energized, there is an inrush of adjust voltage levels. Transformers
current to bring it from a residual consist of a primary coil and a
flux level to normal steady state flux secondary coil. The coil winding of a
level. Transformers have inductive transformer can be tapped to change
characteristics similar to motors the turns ratio and adjust the voltage
when charging, with inrush level of a system. Refer to Figure
(magnetizing) current as much as 40 53.
times full load current when
connected to a utility power source.
With a generator source, values of
generator subtransient reactance
(X”d) limit the inrush current to
values of 6 to 10 times generator
rated current. However, the process
Figure 53
of flux build-up in transformer
excitation takes only a few cycles
Example:
before current returns to a relatively
To better understand transformer
low exciting current level. The effect
taps, consider the 4160 V to 480 V
on the generator set can be ignored,
distribution step-down systems V. Keep in mind that the tap adjusts

shown in Figure 54 and Figure 55. the overall voltage level. It does not
On the system, voltage is dropped change the voltage spread. In this
from 480 V at the bus to 450 V at example, voltage at the transformer
the load. But, what if that load would have been increased from
required more voltage than 450 V 480 V to 504 V. An automatic
from the 4160 V generator? regulator on a generator set could
have also been used to adjust overall
Solution: voltage, instead of a transformer
One way to remedy the situation is tap.
with a –5% transformer tap, which
increases voltage at the load to 474
Figure 54
Figure 55
Transformers have a variety of from the power source is used.

taps. Table 20 is an example of taps Voltage variations of ±10% are
found in a 4160-480 V transformer. usually acceptable since electronic
circuits sensitive to voltage
variations contain internal regulation
4160-480 Volt Transformer Taps
circuitry.
Primary Secondary
Tap
Voltage Voltage Power for complex telephone
3952 480 –5% systems is frequently supplied from
4056 480 –21⁄2% building system mains. Voltage and
4160 480 Normal rating frequency stability requirements are
4264 480 +21⁄2% usually not severe, however solid-
4368 480 +5%
state battery charging equipment
Table 20 may be part of the load and create
disturbance to a generator power
Critical Loads source.
Critical loads are loads that cannot
tolerate voltage and frequency dips. Medical Equipment
Data centers, communication X-Ray equipment typically needs
equipment and medical equipment very short duration, high voltage
are examples of critical loads. from power supplies. This need
results in high current draw in short
Data Centers/Computers durations, which in turn results in
Data centers require a reliable low kW demand at near unity power
power source. Power quality factor.
requirements should be considered
Power source equipment should be
prior to power system design. As a
selected to maintain x-ray quality.
rule, avoid heavy SCR loads, block
As x-ray equipment is activated,
switching loads and large motor
voltage dip due to inrush should be
skVA on data processing equipment
within 10% or within the
power circuits.
manufacturer’s recommended
Communications Equipment tolerance.
Communication equipment includes These loads generally represent
broad ranges of electronic devices only a small part of the generator
for transmission of information. load, so x-ray pictures are not
Most common are radio and normally affected.
television broadcasting equipment,
studio equipment, transmitters and Helpful Load Application Tips
telephone equipment. Generally, all Some general rules can be used if
devices pass their power supply the smallest but most effective on-
through transformers. Therefore, site system is required:
power factor is slightly less than • Across-the-line motors when
unity. Most equipment tolerates started, should always have
frequency variations of ±5%, the largest motor started first
except where synchronous timing
and then smaller motors load. Line voltage drop change with
sequentially after that. load change also affects voltage
• When motors with electronic regulation at the load, if the load
drives are started, the “largest varies.
motor first” rule does not Power losses are calculated as I2R
necessarily apply. Electronic loss in watts or kilowatts. Voltage
drives allow better control of drop is calculated as I2R loss. The
the load by controlling the amount of resistance is based on
maximum current load and length, cross-sectional area,
rate of load application. These temperature, and substance of the
loads are more sensitive to conductors. Standard electrical
voltage variation than the handbooks contain tables of
motors started “across-the- resistivity of wire and cable for
line”. making calculations. Line losses are
• When UPS loads are present, not typically a factor with short
load them last. Generators are cable lengths of proper size.
more stable and less affected Power Factor Loads
by non-linear loads when Self-excited, synchronous
linear loads have been running generators are not designed to
before non-linear loads are operate with leading power factor
applied. load. The AC voltage generated is
• Loads that have filters or use controlled by DC excitation. The
power factor correction for amount of excitation required is a
power quality improvement function of generator load.
should not be applied to a Excitation required to maintain
light load level. The capacitive constant voltage increases with
elements of these loads make load. Reactive lagging power factor
the generator susceptible to load requires more excitation than a
huge voltage increases. unity power factor load. Leading
Line Losses power factor loads require less
Wires and cables in circuits always excitation than unity power factor
have some resistance to current loads. When a generator has a
flow. This presents a power loss and leading power factor, the armature
a voltage drop. The losses are a flux reacts additively with the field
function of line length and line pole flux to increase saturation and
current carrying capability. These produce a higher terminal voltage for
losses must be considered. a given amount of excitation. The
automatic voltage regulator responds
Line voltage drop may be a more to control voltage by reducing
important consideration. Voltage excitation. At light load, the
drop can represent a significant regulator will go to its minimum
difference between generated excitation capability. However, the
voltage and voltage delivered at the additive excitation from a leading
power factor will cause the terminal set application. However, as can be
voltage to rise and will not be seen by the equivalent circuit of a
controlled by the voltage regulator. transmission line, there is distributed
It is not uncommon for this capacitance between the lines and
condition to occur with power factor ground; refer to Figure 56.
correction capacitors or tuned circuit The line charging current varies
filters, which are connected to with voltage, length, height, and line
circuits at light load conditions. This spacing along with other factors.
same phenomenon can occur when A problem arises, particularly with
energizing long transmission lines an unloaded line, where the line
due to distributed capacitance. charging load appears as a leading
Adding reactance to the circuit is a power factor load to the generator.
possible solution to overcome the Power factors of 0.95 leading or
problem should it occur. more may result in the generated
Long Transmission Lines voltage going uncontrolled to the
Long transmission lines may limit of the generator saturation
require the effects of distributed line curve upon energization of the line.
capacitance to be taken into Having some lagging reactive load
account. The definition of a “long” on-line will correct or avoid this
transmission line is a relative term problem should it occur.
and difficult to define for a generator
Figure 56
Two-wire Circuit Power Loss Three-wire Circuit Power Loss

Formula Formula
The formula for calculating the The formula used to calculate
power losses for a two-wire circuit power for a three-wire circuit
(DC or single-phase) is: (assuming a balanced load) is:
24 x L x I2 36 x L x I2
=P =P
CM CM
Where: Where:
P= Power Loss in Watts P= Power Loss in Watts
L= One-way Length of a Circuit L= One-way Length of a Circuit
in feet in feet
CM = The Cross Section of a CM = The Cross Section of a
Conductor in Circular Mils Conductor in Circular Mils
I= Represents Current I= Represents Current
Example Example
Assume a single-phase motor rated Assume a three-phase motor rated
to deliver 7.5 hp at 115 V is to deliver 100 hp at 230 V
connected to a power source via a connected to the power source via a
200 foot, No. 1 AWG copper wire 400 foot cable sized at 250 MCM.
sized at 83,690 CM. Also, assume Also, assume the motor draws 248
the motor draws 80 amperes at full amperes at full load. What is the
load. What is the power loss? power loss?
Solution Solution
Use the formula for a single-phase Use the formula for a single-phase
motor: motor:
24 x 200 x 802 36 x 400 x 2482
=P =P
83,690 250,000
The result is a 367 watt power The result is a 3,543 watt power
loss. loss.
Single-Phase Loads three-phase kVA capacity),

In three-phase power generation, a unbalanced single-phase loading is
single-phase load is a load placed not cause for concern provided any
across one voltage phase of the of the three line currents do not
generator. exceed the generator set rated line
current.
If single-phase loads are added to
the three-phase system, a condition To determine the maximum single-
of unbalance will exist unless the phase load which may be safely
single-phase loads are equally drawn from a generator set
distributed among each of the three supplying single-phase and three-
phases of the generator set. phase power simultaneously, use
Tests have shown that phase- Table 23 on Page 90 to help with
calculations.
voltage unbalance of more than 2%
in three-phase will cause motor Example 1 (Closed Delta Generator)
overheating if the motor is operating Refer to Figure 57. Find the
close to full load. Some electronic amount of single-phase power which
equipment may also be affected by can be safely drawn from a three-
an unbalance of more than 2%. phase 120/240 volt four-wire
Load Balancing generator set rated to deliver 100
If the electrical distribution system kW at a 0.8 power factor. The coil
served by a three-phase generator current rating of the generator set is
set consists entirely of three-phase 334 amperes. Assume that the
loads, the system is balanced. The single-phase load is connected from
coils making up the generator’s one line-to-neutral, has an operating
three phases each supply the same power factor of 0.9 lagging and that
amount of current to the load. If the generator set is supplying a
single-phase loads are added to the three-phase load of 50 kW at a
power factor of 0.08.
three-phase load, however, a
condition of unbalance will exist
unless the single-phase loads are
equally distributed among each of
the three phases of the generator
set.
Generators operate best with
balanced loads. If the loads are
unbalanced, the risk of overheating
is probable. When sizing a generator
all loads should be balanced.
Figure 57
In many applications, balancing of
single-phase loads may not be
practical. If these loads are small
(10% or less of the generator set
Solution 1
1. First, find the current drawn
from each of the lines by the
three-phase load.
1.732 x I x pf x V P x 1000
P= I=
1000 1.732 x V x pf
Figure 58
50 x 1000
= 151 Amperes
1.732 x 240 x 0.8 Solution 2
1. First, find the current drawn
2. Find the coil current capacity from each of the lines by the
remaining for the single-phase three-phase load.
load: 1.732 x I x pf x V P x 1000
P= I=
334 – 151 = 183 amperes 1000 1.732 x V x pf
3. Find the single-phase power 50 x 1000

= 173.5 Amperes
available: 1.732 x 208 x 0.8
V x I x pf 120 x 183 x 0.9
P= = = 19.8 kW 2. Find the coil current capacity
1000 1000
remaining for the single-phase
load:
Example 2 (Wye Generator)
Refer to Figure 58. The generator 334 – 173.5 = 161 amperes
set is rated to deliver 100 kW at a
0.8 power factor. It is a three-phase 3. Find the 208 volt single-phase
machine with a coil current rating of load current:
334 amperes. The three-phase load
P x 1000 10 x 1000
to be supplied is 50 kW at 0.8 I= = = 60 Amperes
V x pf 208 x .08
power factor. The single-phase load
consists of both 120 and 208 volt
circuits. The 120 volt load has a 4. Find the coil current capacity
power factor of 0.9 and is remaining for the single-phase
connected from neutral to one leg. 120 volt load:
This leg is common with one of the 161 – 60 = 101 amperes
two supplying 10 kW at a 0.8 power 5. Find the 120 volt single-phase
factor to the 208 volt load. power available:
V x I x pf 120 x 101 x 0.9
P= = = 10.9 kW
1000 1000
Example 3
Refer to Figure 59. Similar to the
previous example, the generator set
is rated to deliver 100 kW at a 0.8 3. Find the 120 volt single-phase

power factor. It is a three-phase power available:
machine with a coil current rating of V x I x pf 120 x 173.5 x 0.9
334 amperes. The three-phase load P= = = 18.7 kW
1000 1000
to be supplied is 50 kW at 0.8
power factor. The single-phase load
consists of both 120 and 208 volt One-line Diagrams
circuits. The 120 volt load has a One-line diagrams greatly simplify
power factor of 0.9 and is load and system analyses.
connected from neutral to one leg.
Different from the previous example,
this leg is not common with one of
the two legs supplying 10 kW at a
0.8 power factor to the 208 volt
load.
Figure 60
The one-line diagram shown in

Figure 60 represents a balanced
system. In the top diagram, the
generator is shown in its three
Figure 59 phases, which are separated with an
ELN line-to-neutral voltage. XS
Solution 3 (Wye Generator) represents generator reactance. RL
1. First, find the current drawn and XL are load resistance and load
from each of the lines by the reactance, respectively. The middle
three-phase load. diagram illustrates the single-phase
1.732 x I x pf x V P x 1000 equivalent of all three phases. The
P= I=
1000 1.732 x V x pf bottom diagram is a further
simplification of the same thing. A
50 x 1000 simplified diagram is often used in
= 173.5 Amperes three-phase representation.
1.732 x 208 x 0.8
Example 4, Generator Set Sizing
2. Since the 120 volt is the only In all of the following steps, Figure
single-phase load on this leg, 61 and Figure 62 will be used to
the coil current capacity detail how to size a Caterpillar
remaining for the single-phase generator set, using load
120 volt load is 173.5 amperes. information; Figure 62 is used when
motors with NEMA code letters are
considered.
1. Using information from the

nameplate, fill out information in Approximate Efficiencies of
Part I and II. The motor Squirrel Cage Induction Motors*
efficiency can be estimated hp kW
Full-Load
using a chart of approximate Efficiency
5 to 7.5 4-6 0.83
efficiencies in Table 21.
10 7.5 0.85
15 11 0.86
20 to 25 15 to 19 0.89
30 to 50 22 to 37 0.90
60 to 75 45 to 56 0.91
100 to 300 74.6 to 224 0.92
350 to 600 261 to 448 0.93
* Efficiencies are significantly influenced
by the motor class.
Table 21
Figure 61
Figure 62
2. Total engine load is determined requirements by starting the

by calculating motor efficiencies largest motors first. The motors
and adding to resistive load; add rating and NEMA code can be
the lighting loads, other non- found in Section II. The
motor loads and motor loads skVA/hp is found using the
together. NEMA code letter from Table 14
3. Select engine (Part IV) which on Page 49
matches frequency (Hz), Find the Starting skVA using the
configuration (gas, diesel, following formula:
turbocharged, aftercooled, LRA x V x 1.732
skVV =
naturally aspirated), speed and 1000
load. Hz and configuration are
found in Section I. Speed is by 5. Motors on-line diminish skVA to
customer preference and the start additional motors. For item
load was determined in Section B1 - column 1, the first motor is
II. always zero if there is more
4. Generator Sizing: In Section V than one motor. Motor #2 space
fill in Part A for all motors from is the kW in Section II from first
nameplate. Minimize starting sequence motor. Additional
motor’s kW are added to the

total for each motor starting. Reduced Voltage Starting Factors
The items in the B2 row are Type Multiply
filled in using Section II skVA By
information as written. The Resistor, Reactor, Impedance
items in the B3 row use the 80% Tap 0.80
Motor Preload Multiplier formula 65% Tap 0.65
50% Tap 0.50
to determine the percentage of
45% Tap 0.45
motor load.
Autotransformer
The Motor Preload Multiplier 80% Tap 0.68
formula is B1 divided by B3 or: 65% Tap 0.46
All Motors Running 50% Tap 0.29
% Motor Load = X 100
All Motors Running & Being Started Y Start, Run 0.33
Solid State: Adjustable, consult manufacturer
Under 40%, the multiplier is 1.0. or estimate 300% of full load kVA (Use 1 if no
Over 40%, use a value from the reduced voltage starting aids used)
chart in Figure 63. Table 22
Motor Preload Multiplier If no starting aid is used, use 1.0.

Row B8 can be filled by using
information in Section II.
6. Use the effective skVA and
Acceptable Voltage Dip
numbers to find on TMI the
appropriate generator. Fill in C1,
C2 and C3, using the numbers
from TMI.
7. Generator set sizing (VI) can be
found by selecting the largest
generator set model of step IV
and step V. (C1).
Figure 63
If reduced voltage starting is used,

multiply the skVA by the factor
found in Table 22; fill in spaces for
rows B6 and B7.
kVA of AC Circuits
Table 23
Genset Selection Considerations

When choosing a genset these Linear Loads
factors need to be considered: Linear loads are defined as
• Load Type alternating current (AC) loads which
draw current proportional to voltage.
• Load Steps
They draw current evenly, in sine
• Load Balance waveform, throughout the cycle.
• Generator’s The load may be resistive, inductive
(lagging power factor) or capacitive
o Temperature Rise
loading (leading power factor).
o Pitch Regardless of the type, current
o Voltage Range drawn by a linear load will remain
sinusoidal.
Load Types Conventional electrical formulas for
All loads are different in their determining electrical characteristics
power quality needs. A simple such as voltage drop, current flow
incandescent light bulb does not measurement, power consumption
demand high quality power. The and heating values are applicable to
amount of light will drop linear loads and assume there is no
proportionally to voltage, but distortion of voltage and current
frequency and voltage waveform waveforms.
free from distortion is not
significant. Other loads are sensitive Typical linear loads are:
to those type voltage variables. • Incandescent Lights
Loads are typically defined as linear • Resistance Heaters
or nonlinear. One of the first steps is
• Induction Motors
to separate loads into linear and non-
linear loads. Table 24 provides • Synchronous Motors
examples of linear and non-linear • Electromagnetic Devices
loads.
• Transformers (non-saturated)
Voltage and
Current Drawn Current Examples
Waveforms
Linear Proportional to Sine wave Incandescent light bulbs
voltage Induction and synchronous
motors
Electromagnetic devices
Resistance heaters
Non-Linear Non-proportional Pulses Silicon controlled rectifiers
to voltage Variable speed drives
Uninterruptible power
supplies
Battery chargers
Fluorescent lighting
Table 24
Typical non-linear loads are:

Non-Linear Loads
An electrical load which changes • Silicon Controlled Rectifiers
or modifies the current or voltage • Variable Speed Drives
waveform to one that is not
• Uninterruptible Power
sinusoidal is a non-linear load. A load
Supplies
that draws current in pulses is a
non-linear load. • Battery Chargers
The development and application • Computing Equipment
of solid-state electronic components • Fluorescent and Gas
has proliferated nonlinear electrical Discharge Lighting
loads. Semi-conductors, particularly • Transformers (saturated)
silicon controlled rectifiers (SCR’s)
have the ability to turn “on” or begin All of these devices require
conducting at any point during the current, which cannot be provided
applied volt wave and draw without causing some distortion to
instantaneous pulses of current. the applied source voltage. Non-
These instantaneous pulse demands linear loads in the system can cause
result in harmonics, which result in problems for other loads.
the nonlinearity.
Another source of non-sine wave
current drawing loads is saturated
magnetic core equipment, such as
fluorescent ballast transformers and
saturated core reactor regulators.
Total Harmonic Distortion (THD) is

Harmonic Content
the measurement of the sum of all
Deviation from a pure, single sine
harmonics. Most loads will continue
wave can be expressed as additional
to operate with THD at 15 to 20%.
sine waves of frequencies, which
However, loads with sensitive
are a multiple of the generated
electronic equipment can develop
frequency. These additional
problems with THD greater than 5%.
frequencies are called harmonics.
Non-linear loads cause harmonic
Because three-phase generators
currents. These harmonics can
are magnetically symmetrical,
cause control problems and internal
resulting in the cancellation of even
heating of the generator limiting its
harmonics, only odd harmonics are
capability. Generators are designed
normally of any significance. For
to provide a given output at rated
example, a 60 Hz generated
frequencies of 50 or 60 Hz. It is
waveform will contain the 60 Hz
possible for a generator to carry less
fundamental; a 180 Hz, 3rd
than its full rated current and yet
harmonic; 300 Hz, 5th harmonic;
overheat because of a harmonic
420 Hz, 7th harmonic and so on.
current generated by non-linear load.
Table 25 shows both even and odd
Form-wound machines typically
harmonics of a 60 Hz generated
provide better performance in high
waveform.
harmonic applications.
A 50 Hz generated waveform will
In cases where non-linear loads
contain the 50 Hz fundamental; a
cause increased generator heating,
150 Hz, 3rd harmonic; 250 Hz, 5th
two techniques are typically used to
harmonic; 350 Hz, 7th harmonic and
compensate for the increased
so on.
generator heating. Deration is one
In general, the higher the harmonic method and using a generator that is
order, the lower the magnitude of oversized for the kVA requirement is
the harmonic. another.
Harmonic Frequency Sequence

Fundamental 2nd 3rd 4th 5th 6th 7th 8th 9th
60 120 180 240 300 360 420 480 540
Table 25
Figure 64
Figure 65
Figure 66
harmonic distortion to be created by

Generator Considerations a non-linear load. Current reacts
Generator Heating with impedance to cause voltage
Generators are designed to provide drop. The internal reactance of a
a given output at rated fundamental generator to instantaneous current
frequencies of 50 or 60 Hz. Design change is the direct axis
considerations include making the subtransient reactance (X”d). A
most effective use of active material generator with the lowest per unit
to meet acceptable limitations of value of X”d at a given load will
temperature rise. (More on this topic typically have the lowest value of
is found in Engine Ratings section.) total harmonic distortion under non-
linear load conditions.
Generator Reactance Impact
Subtransient reactance (X”d) is a The internal reactance of a
primary indicator of the amount of generator due to line-to-neutral or
unbalanced loading is the zero loads are connected to the generator

sequence reactance (Xo). Any 3rd bus line-to-line, without a neutral
harmonic currents, also known as connection or supplied through
triplen harmonics, produced by the delta-wye transformer, any triplen
load will not cancel in the neutral harmonics, caused by the load, are
and the result is neutral current not recognized by the generator.
flow, even with balanced loads. The This harmonic blocking effect,
triplen harmonic circuit is the same although desirable to the generator
as three single-phase circuits with and other parts of the distribution
three parallel line-to-neutral branches system, can lead to excessive
sharing common neutral. transformer heating.
Phase conductor heating from the Generators operating at 400 volts
100% rated neutral 3rd harmonic or higher typically supply loads
current and other effects will add through delta-wye distribution
approximately 6 to 7% of additional transformers. Exceptions to this may
heat. This relatively high 3rd occur; of special concern is where
harmonic would only require 6 to gas discharge lamps are connected
7% derating of the generator. It can directly to the generator bus at line-
create distortion of the generator to-neutral voltage, without benefit of
voltage waveform and consequently, harmonic reduction techniques.
could have effects on circuit Smaller generators (typically below
protective devices and other external 100 kW) often power the load
circuit elements. directly at 208/120 volts with a wye
If the load generates 3rd connection. Whenever loads are
harmonics, the neutral current may connected directly to the generator
become quite large. The generator bus, line-to-neutral, the possibilities
will actually tolerate a fairly large of 3rd harmonic current should be
amount of 3rd harmonic current flow considered.
in the neutral with a moderate Waveform Distortion
increase in generator heating.
Waveform distortions are greater
It is not uncommon for a facility to on a genset than when the loads are
have large banks of fluorescent connected to utility power. A
lighting and/or single-phase personal generator can be compared to others
computing equipment circuits; by the level of distortion when
creating large amounts of 3rd running at full load. Since larger
harmonic current. A neutral loads increase harmonics, full load
conductor larger than the should be used for accurate
conventional half-rated neutral may comparison. Typically, a 5% or less
be required for these circuits. THD is specified, with no more than
Fortunately, the design of many of 3% from any one harmonic.
these facilities includes steps to
The magnitude of a voltage
reduce 3rd harmonic current before
waveform distortion caused by the
they reach the generator. Where
non-linear current demand of the
rectifier/charger is a function of the functions such as HVAC systems,

source impedance. Source chilled water systems, fire protection
impedance is not an easily defined systems, and room lighting must
value as generator reactance varies also be connected to the standby
with time following a sudden load generator set. These support
change. Generator subtransient systems are often as large, or larger,
reactance (X”d) and subtransient than the UPS load. It is frequently
short circuit time constant (T”d) are very desirable for system operation
primary parameters which influence and distribution reasons to have
distortion during the short duration small, three-phase, continuously
of SCR commutation periods. running air handler motors in the
A standby generator is computer and UPS room sharing a
characteristically of higher common feeder or power
impedance than a transformer. transformer with the UPS.
Further contributing to the Resistive loads are effective in
impedance difference is often a minimizing waveform distortion
significant difference in kVA rating caused by “ringing effect”.
in the two sources. Where as a Resistance acts as a damper to
facility source transformer is oscillation in a resonant circuit.
frequently sized to carry the total Adding a resistance load is one
facility load, the standby set is often technique used as a treatment to
only sized to carry the emergency or minimize waveform distortion
critical loads. A generator may have caused by system oscillation. This,
5 to 100 times greater subtransient however, is only effective if high
reactance than the normal source frequency oscillations are the cause
transformer. of the problem. If a resistance
Consequently, non-linear loads element is added strictly for
which work fine on utility, may react treatment purposes, the addition of
entirely different when powered by a a capacitor in series with the resistor
generator set. Using an oversized will reduce fundamental current with
generator to reduce reactance may minimum effect on high frequency
be of some benefit. However, to damping.
obtain a significant reduction in Adding a low pass filter to the
reactance is not usually generator output for attenuation of
economically feasible. A doubling of prevailing harmonics is theoretically
generator rating is required to reduce possible, however, should be
reactance by one-half. considered a last resort option.
Damping with other loads reduces Practical tuned circuit filters
effective bus reactance. Motors, in generally represent compromise and
particular, act as absorbers of may introduce more problems than
momentary voltage irregularities and they solve. Component size and
reduce harmonic content on the line. expense are also limiting factors. A
Typically, computer room support better approach is to specify or add
filtering or other harmonic distortion from the load. A well-

attenuating options such as isolation filtered regulator combined with the
transformers at the source of inherent inductive filtering of a
distortion. Consultation with the brushless design generator virtually
UPS supplier will usually reveal such eliminates this problem. The self-
available options. excited generator has a well-filtered
Generator AVR and Excitation regulator and excitation system
The voltage regulator must control which provides voltage control and
output voltage of the generator in stability of equivalent quality to that
spite of the load causing a distorted obtainable with a permanent magnet
wave shape. Various techniques can pilot exciter. It is also fully capable
be used to accomplish this task. of sustaining excitation during the
short circuit periods occurring during
Three-phase sensing minimizes the commutation of load SCR’s
effects of waveform distortion by without the benefit of excitation
providing an average of all three sustaining options. A permanent
phases at any given instant. Since magnet exciter, while capable of
the SCR’s in three-phase rectifier sustaining excitation during a
loads do not all “gate on” at the sustained fault condition, has no
same instant, a minimized distortion advantage in providing excitation
average signal of the three phases is during the short duration of load
processed. In comparison, a single- SCR commutation. Additional
phase sensing regulator will sense regulator filters or optional features
severe distortion occurring at a given are not required for all generators for
instant during the cycle in one UPS applications.
phase. The generator has a three-
phase sensing network with a Determining Distortion
floating neutral as a standard A review of the entire generator
feature. Thus, voltage disturbance in set distribution system should be
any one phase will shift the neutral made to determine if loads exist
but not appreciably affect the which require a source with low
voltage to the regulator. Waveform distortion waveform. Unless the
notching is effectively blocked from generator set system is large, it is
the regulator. quite common for other loads to
share a common bus with the UPS.
Regulator circuits must include
If distortion-sensitive loads are
features to isolate field power
suspected, a consultant or
control from effects of distortion. If
distribution system designer with
SCR’s are used within the regulator,
knowledge of where harmonic
circuits must be used to prevent the
distortion might be adverse and how
distortion from load SCR’s
to avoid it should be contacted.
interfering with triggering of
regulator SCR’s. To calculate total harmonic
distortion at a point in the
Generator field power must be
distribution system requires the
filtered to minimize interaction with
consultant to have access to system copper and provides little harmonic

data such as subtransient reactance control. Most generators are
and kVA rating of the generator and fractional pitch windings.
any other rotating machines, The magnitude and frequency of
reactance and resistance’s of harmonics generated by the machine
transformers, cables, and other will vary with the pitch factor and
circuit elements as well as other design parameters.
characteristics of the non-linear,
distortion producing device. 2/3 Pitch
The 2/3 pitch winding became
The impact of generator pitch on
popular when manufacturers of
load generated harmonic currents is
small generators wound their
highly dependent on the system
machines in delta to combine three-
configuration. This too, is typically
phase and three-wire single.
not consequential except in special
Generators with 2/3 pitch are
cases. When supplying non-linear
sometimes thought to have an
loads which have no neutral
advantage with non-linear loads
connection, the coil pitch has no
because of their low zero sequence
effect on voltage waveform
reactance (Xo — a low reactance to
distortion.
3rd harmonic zero sequence
Generator Pitch current.). However, 3rd or triplen
Generators do not generate a harmonics are not normally present
perfect sine wave. Consequently, in three-phase rectifier loads, such
there are some harmonics generated. as encountered with UPS or variable
To produce voltage, a synchronous speed motor drives, and this
generator has a direct current (DC) characteristic becomes insignificant.
excited structure consisting of Additionally, a 2/3 pitch generator
alternating north and south magnetic typically generates higher 5th and
poles, usually on the rotating 7th harmonics which will cause
member of the generator or rotor. additional heating in motors due to
The magnetic field produced, the higher frequency. In cases with
sweeps the armature (usually the single-phase non-linear loads
stator) and induces voltage in coils connected line-to-neutral directly to
placed in slots in the armature. the generator bus, the 2/3 pitch
When the span of each of these generator has the potential to
coils is exactly equal to the span of minimize, but not totally prevent,
the north to south field poles, the 3rd harmonic, (load created) voltage
maximum magnetic flux is waveform distortion.
encompassed by the coil and the Non-Linear Loads and 2/3 Pitch
maximum voltage is produced. Such Non-linear loads generate harmonic
a positioning of coils is called an “all currents which cause waveform
pitch” winding. Very few machines distortion of the generator. For
are wound full pitch because the balanced three-phase loads,
winding requires excessive end turn distortion is caused by voltage drop
due to the harmonic currents in the is of the most significance.

subtransient reactance of the Reactors, resistors, or switches can
generator. The subtransient be installed to limit these currents.
reactance of a generator is not a Applications Requiring 2/3 Pitch
function of coil pitch. Therefore, the
When paralleling, it is desirable to
coil pitch does not affect waveform match the pitch of the existing
distortion.
generators. If the existing generators
The zero sequence reactance of a have 2/3 pitch another generator of
generator is effective only to matching 2/3 pitch is preferable.
currents which flow in the neutral Single-phase non-linear loads that
line. Single-phase non-linear loads are connected in a balanced manner
usually generate high 3rd harmonic with a neutral connector directly to
currents. When these loads are the generator is also an acceptable
connected in a balanced manner to a application of a 2/3 pitch. An
three-phase generator, the 3rd example of this is a 277 V lighting L-
harmonic currents add in the neutral N.
to produce very high neutral
Other Generator Set Selection
currents.
Considerations
Only where the load is connected There are times that a facility will
directly to the generator does the have reconnection issues. For
low zero sequence reactance of a example, if a genset is being placed
2/3 pitch generator reduce the at a site and then moved to another
voltage waveform distortion. If the site (with perhaps different
load is supplied through a Delta-Wye applications) the generator set will
transformer, the 3rd harmonic have to be sized to meet the
currents do not appear in the different requirements of both sites.
generator and the 2/3 pitch winding It is also possible that a customer
does not help reduce distortion. will know that the facility will be
Paralleling and 2/3 Pitch rewired from 480 V to 240 V. Such
Paralleling generators of different a situation will require additional
pitch can cause harmonic distortion. consideration when sizing the
A circulating current will flow generator set.
between paralleled generators if they Voltage Range/Number of Leads
do not have equal generated voltage The voltage range and the number
waveforms. The flow is dependent of leads need to be considered so
upon the voltage difference. In some that a generator set can be matched
cases, there may be no advantage to to the job at hand.
2/3 pitch winding when paralleling.
Phases are typically arranged in a
When paralleling with a utility the wye configuration as shown in
2/3 pitch winding may be a Figure 67 or a delta configuration as
disadvantage due to low zero shown in Figure 68.
sequence reactance. Typically, 3rd
harmonic current flow in the neutral
WYE Connection 70 shows a six lead delta

connection.
Six Lead WYE Connection
Figure 67
Delta Connection Figure 69
Six Lead Delta Connection
Figure 68
The wye phase connection has a

neutral point, often connected to
ground. The delta does not have a Figure 70
neutral point. The wye configuration
A twelve-lead wye connection is
is used with three-phase loads or
the most common in North America.
line-to-line loads. Delta connections
It allows the most versatility
are used with single-phase and
because of the multiple
three-phase loads. Delta connections
configurations allowed.
are found in rural communities
where three-phase is not available. A A twelve-lead, wye connected,
generator can lose up to half of its 480 V generator set is usually
rating if a delta configuration is required for large air compressors,
hooked to a three-phase system. It motors, chillers, and air handlers.
is most common for generators to 240 V is typical for smaller three-
have 12 or 6 leads. Figure 69 shows phase motors. 120 V is common for
a six-lead wye connection and Figure office equipment and small single-
phase motors.
Before choosing a generator set,

the current coming in must match
the neutral lead. If they do not
match, current will be lost in the
generator which will weaken the
insulation. Alternators would be
more susceptible to contamination
and failure. Differential protection is
a preventative item which checks
the current and determines if the
neutral matches the incoming
current. Figure 71
Genset Voltage Selection
Caterpillar identifies three voltage Multi-Engine Installations
types: In some situations, the use of more
than one generator set is mandatory.
• Low
In others, it may prove more
• Medium economical to have more than one
• High genset. When the load is too large
Low voltage is the voltage on a for a single unit, two or more
local level or part of a site. 600 V or gensets may operate in parallel by
less with 800 kVA is the range for being electronically connected.
low voltage rating. Critical installations in which the
Medium voltage is a low-level prime power source is a generator
distribution rating. This voltage is set may require additional backup
distributed to power residential sites power. A second generator set
and other campuses. 601 V-5000 V capable of carrying critical loads
with 5-10 MVA is the range for the should be made available in case of
medium rating. primary set failure and for use during
prime set maintenance periods.
High voltage runs over regions and
is the voltage at a utility or the Cases where multiple generator set
national grid. 5001 V-15,000 V installations may prove more
used with MVA’s greater than 10 economical are those where there is
are considered High Voltage. a large variation in load during the
course of a day, week, month, or
Figure 71 shows a voltage versus
year. Such variation is typical in
kVA chart, indicating low, medium
plants in which operations are
and high voltage selections.
carried on primarily during the day,
Depending on what voltage type is while only small loads exist at night.
applicable, will help determine the The more closely a generator set
size of the generator needed. comes to being fully loaded, the
greater the fuel economy per
kilowatt produced. Therefore, the
use of a small genset to power light, tripped to complete the paralleling. If

off-hour loads, will often result in phase sequence is not matched, the
long-term fuel economy. lamps will never be light or dark at
In installations where the load does the same time.
not vary to the extremes A synchronizing meter such as a
encountered between day and night synchroscope, shown in Figure 73
conditions, it is sometimes profitable and Figure 74, can be used instead
to share the load between several of the synchronizing lights for
small units operating in parallel. synchronizing two or more generator
When the load is lighter, one or sets. The direction the pointer
more of the units may be shut rotates indicates whether the
down; thereby loading the other frequency of the incoming generator
units closer to capacity. For is slower or faster than the
example, this type of system is frequency of the on-line generator.
advantageous where load demand is Similarly, the frequency at which
seasonal or when maintenance is the pointer rotates indicates the
necessary and power interruption magnitude of difference in speed
must be avoided. between the generator sets. For
Paralleling paralleling, engine speed is changed
Generator sets can be paralleled to until the synchroscope pointer
other generator sets or the utility. To rotates very slowly (less than 10
operate in parallel, both units must rpm), again keeping the incoming
match phase sequence, voltage generator set faster than the on-line
frequency, manage neutral currents, generator set. When the pointer is at
operate with the same frequency the zero position, the circuit breaker
directional rotation and produce can be closed, thereby synchronizing
almost exact sine waves. Only after the units.
these conditions are met can the
units be connected together by a
breaker.
Synchronizing lights or meters are
used in a manual paralleling
operation to confirm both rotational
requirements and phase voltage
requirements have been met.
Automatic, electronically controlled
measuring devices are used in
automatic paralleling.
The synchronized lights have
lamps, shown in Figure 72, that dim
and brighten. When the units are in
phase, the lights are at their
dimmest and the breaker can be
Figure 72
Example of a Synchronizing Meter
Figure 73
types, imbalance during

transient load changes can be
anticipated.
As load is suddenly applied,
constant voltage units attempt to
supply the total requirement. As the
constant voltage generator drops
frequency, the volts-per-Hertz unit
begins to share load. The temporary
Figure 74
load imbalance passes, and kW load
Usually, identical generator sets is shared between generators.
operate in parallel without problems. Once two or more generators are
When paralleling unlike units, paralleled, it is as though they are
however, the following effects must mechanically coupled together. They
be considered. will operate at the same speed but
• Engine Configuration: not necessarily have the same
Response to load changes will power output. Each engine’s power
be affected by engine size, contribution is controlled by the
turbocharger, governor type, relative fuel system output.
and adjustment. Temporary Droop and Governors
unbalance of kW loads during Droop is when the governor
load change is likely, but can reduces speed with an increasing
quickly stabilize. load. Speed is lowest at full load and
• Generator Design: Circulating highest at no load. Droop is
currents and harmonic expressed as a percentage of rated
currents add to basic load speed. A 2 to 3% droop is typical.
current, increasing coil Two isochronous units, operating
temperatures, and causing in parallel, will operate at constant
circuit breaker tripping. speed (no droop) and be stable at
Circulating current is either no load or maximum load.
minimized by correct regulator Loads in between will shift randomly
adjustment. Harmonic between the two generators.
interaction between Electronic governors can be installed
generators must be calculated to limit this instability by causing
to determine compatibility. load to be shared more evenly. This
• Regulator Design: Automatic strategy is especially effective in
or analog voltage regulation allowing many units of unequal size
(AVR) of dissimilar design to share load in proportion to their
may be used when paralleling size.
generators. When constant An isochronous generator can also
voltage regulators are be paralleled with a droop unit. If
paralleled with volts-per-Hertz load is normally at 50% or more
then the droop unit can carry the Regulator Compensation

load up to 50%. The synchronous When two or more units are
unit then picks up load from 51% to operating in parallel, the regulators
100%. The droop unit can not vary must control the excitation of the
it’s load because its governor can alternators so they share the
only have one rack position at the reactive load. Two methods used to
isochronous speed setting. regulate excitation are:
If the load is normally under 50% • Reactive Droop Compensation
of rated, then the isochronous
• Reactive Differential (cross
speed generator would be set for
current) Compensation
rated speed and carry all loads up to
50%. If load exceeds 50%, the Reactive droop compensation does
isochronous unit slows down and not require a wiring interconnection
the droop unit picks up the between regulators. During parallel
additional load. The isochronous unit droop compensation operation, the
will stay at its reduced speed (the bus voltage droops (decreases) as
same speed as the droop unit), until the reactive lagging power factor
the load falls below 50%. load is increased.
If both units are in droop, load Reactive differential (cross current)
share is automatic after they are compensation requires the addition
adjusted to the same high-idle of interconnecting leads between the
speed. If no load is connected, each current transformer secondaries and
unit will stay at high-idle speed. If allows operation in parallel without
full load is connected, both units voltage droop with reactive load.
must operate at rated speed Cross current compensation can
(governor racks at full load setting). only be used when all the paralleling
All loads between no load and full current transformers on all the
load will act accordingly, although generators delivering power to the
frequency will vary. Since the bus are in the CT secondary
generators must operate at the same interconnection loop. Because of this
speed and a given speed results in requirement, cross current
one rack position with a droop compensation operation cannot be
governor, the generators will operate used when a generating system is
at approximately the same power operating in parallel with the utility
output. power grid. Utility voltage can vary
enough to cause high circulating
current in a paralleled generator.
KVAR controllers must be used to
adjust generator voltage to match
utility and minimize circulating
current.
Load Control Unit Shutdown

There are many decisions which Unit shutdown order is determined
will affect sizing that the facility by analyzing which loads can be
personnel must make. Load spared at certain times while other
prioritization is a decision which loads are still connected. Again,
manufacturer expertise can help maintenance implications need to be
influence or clarify but not dictate. taken into consideration if it is
The end user has to decide upon the determined that the same genset will
load acceptance order, load be shutdown first each time.
shedding order, unit starting order, Redundancy refers to the method
unit shut down order, and/or of purchasing one or more gensets
redundancy. than needed to operate at full load.
Load acceptance order determines This is especially important to loads
which loads are critical and must be where a major percentage of it is
accepted by which generator. critical. With additional gensets,
Load shedding determines which downtime can be kept to a minimum
loads are non-critical and shed so because an additional genset is
that loads that are more critical can always free to be connected. Figure
be given priority or additional load. 75 shows genset #5 as a swing
engine; this engine can be used to
Load Order backup either critical load group if
Site personnel must determine the one of the engines requires service.
order in which gensets will be Major maintenance can be
started. If #1 genset is always performed on a genset while the
started first, it will accumulate hours additional one is connected. If two
and maintenance expenses at a high or more additional gensets are
rate compared to the remaining present then maintenance can be
units. done on two or more or have a
“Slobbering” of the gensets may backup for the system when one is
be another problem encountered. being serviced.
The last unit started may be lightly
loaded and said to “slobber”.
Slobber is a result of lubricating oil
being drawn into the cylinder under
low load conditions. This is not
conducive to long life and good
performance.
A site may require a smaller supply
of electricity on the weekend, when
the loads are not as large. Gensets
of different sizes can be installed
where the larger one(s) supply the Figure 75
week and the smaller the weekends.
LEBE5294-00 ©2005 Caterpillar® Printed in U.S.A.
All rights reserved.

LEBE5294 - Electric Power Applications - Engine & Generator Sizing

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APPLICATION AND INSTALLATION GUIDE

Generator Set Rating Considerations ................................... 2

Information contained in this publication may be considered confidential.

CAT, CATERPILLAR, their respective logos and “Caterpillar Yellow”, as well

Electric Power Applications, Engine & Generator

Generator Set Rating • Demand & Diversity Factors

Generator Set Rating Considerations

Standby Power Continuous Operating Power (COP)

and the Society for Automotive

temperature. In other words, some

a given rating. This will increase

temperature, corrosive atmospheres, The altitude/temperature derating

dip depends on the amount of active

A 30% maximum voltage dip is a lighting is fluorescent rather than

Typical voltage dip limitations are A properly sized generator will

Block Load Transient Response Standards

G1 Required for applications where the General purpose

Table 4 shows the acceptance necessary measures but are not

1. Point 1 is the beginning of the rack stop, the additional fuel

speed is constant for an instant speed is still below rated. Power

Since only governor action is Explanation of Figure 7

Engine Configuration the ability to decrease the transient

For a given displacement, or given Gas Engines

second, with additional time for the Volts/Hz schedules voltage

depending on system design and generator set to function in a more

Estimating Load Data (VA/FT2). In a commercial building,

Load and Power Consumption Estimating Data

Volt Amperes Per Square Foot (VA/FT2)

suggested that the largest loads are consultants, customers and

Zero Import/Zero Export

Concepts of Peak Shaving vs. Peak Sharing

Peak Sharing utility or in parallel so the

As shown in Figure 16, loads are horsepower hour (BHP) of an air

Typical Load Sizing Guidelines

Load Growth Over 10 Years

on the system is 15 kW, which is

To find demand factor use the

Shown in Table 9 is a range of Figure 18 can be used to illustrate

the application. A typical starting and maintain a 100 psi (689.5

Refer to Emergency & Fast Natural Gas

Special engine configurations allow The sulfur present in the fuel

Caterpillar offers standard (STD) Nominal vs. Not to Exceed

Heat Balance customer in terms of performance.

Further definition of linear & non- Lighting Loads

With few exceptions, there are Squirrel Cage

Squirrel Cage Motor Torques in Per Unit

Wound Rotor (Slip Ring) is in the range of 100% full load

reduction of speed with increased Synchronous Motors

squirrel cage motors. Modern Solution

include synchronous reluctance Design C

designer in selection of a motor for a

motor to rated speed. The degree of starting kVA capacity to limit

Table 15 lists standard sizes for 50 determined or the loads will

The rated hp and as starting kVA

engine during starting is calculated required to initially breakaway or

Motor Torque Sample

Breakaway torque depends on the

to the slip required to produce

motor life. Figure 33 reflects typical

Estimated Acceleration Time T= Acceleration torque (lb.

Locked Rotor Current — NEMA MG 1

60 Hz - 230 Volts 50 Hz - 380 Volts

0.5 20 B,D,E 1 or less 20 B,D,E