IMPORTANT NOTE: Power Analytics Corporation’s software products are tools intended to be
used by trained professionals only. They are not substitutes for your professional judgment or for
independent verification and testing of results as they pertain to your specific application. Use of all
Power Analytics Corporation software products is governed by the terms and conditions of the End-
User License Agreement (“EULA”) you accepted when purchasing and installing the software. You
must comply with these terms and conditions in applying the instructional material in this manual. If
you do not have or are unfamiliar with the contents of your EULA for this software, you should
request, read, and understand a copy of your EULA before proceeding.
Please accept and respect the fact that Power Analytics Corporation has enabled you to make an
authorized disk as a backup to prevent losing the contents that might occur to your original disk
drive. DO NOT sell, lend, lease, give, rent or otherwise distribute Power Analytics programs / User's
Guides to anyone without prior written permission from Power Analytics Corporation.
i
Generator Set Sizing
TABLE OF CONTENTS
1 Foreword ...................................................................................................................... 2
2 Introduction ................................................................................................................. 2
3 Capabilities .................................................................................................................. 3
4 How to Run the Program ............................................................................................. 3
5 Sample Problems ......................................................................................................... 4
6 Suggestions .................................................................................................................. 4
7 Sample Screens ............................................................................................................ 5
7.3 Example 1............................................................................................................. 8
7.3 Example 2........................................................................................................... 14
7.3 Example 3........................................................................................................... 16
7.4 Example 4........................................................................................................... 18
7.5 Example 5........................................................................................................... 20
8 Verification and Validation ....................................................................................... 22
LIST OF TABLES
1
Generator Set Sizing
1 Foreword
DESIGNBASE Generator Set Sizing program has been designed to help the design engineer select
generators that satisfy the load requirements of the system under study. In writing this program, it
has been assumed that the user is a Professional Engineer familiar with the subject of selecting
generators to meet distribution system needs.
Determination of validity of the results, and whether the program is applicable to a system, is
solely the responsibility of the user.
This program is undergoing continuous development and refinement. As with all our products,
DESIGNBASE is committed in making the Generator Set Sizing program as current,
comprehensive and easy to use as possible. Any comments, suggestions or errors encountered in
either the results or documentation should be immediately brought to DESIGNBASE's attention.
2 Introduction
In most of the electrical distribution systems located in hospitals, manufacturing plants and high
technology production plants, selection of an Emergency Generating Source is important to:
A -Minimize the down time in order to avoid loss of critical materials and injury to
personnel, etc.
B -Ensure the proper operation of production line, of computers, and continuity of power
supply to the major units in operation that are vital to the product quality.
In selecting a generator design, the engineer should know the following data:
2. -MOTOR CODE LETTER (CODE). The letter is a code for starting KVA per
horsepower. See Table C – MOTOR LETTER DESIGNATIONS (Page 25).
3. -PHASE. Both single- & three-phase motors are available up to 10 HP. Motors above
7.5 HP are usually three-phase ones.
6. -KVA STARTING (LRKVA). Starting KVA required by a motor. For any motor of
given HP & Code letter, the LRKVA draw is the same regardless of phase, speed or
voltage rating on the motor nameplate.
8. -MOTOR RUNNING KVA: the apparent power required by the motor at rated speed
and load.
Generator Set Sizing
9. - MOTOR RUNNING KW: the real power required by the motor at rated speed and
load.
3 Capabilities
The Generator Set Sizing program can tabulate loads and determine both maximum and continuous load
demand by going through the data files to select corresponding information with regard to the industry
standard. User may keep the default data or input own desired information (NAMEPLATE) using the
screen editing capabilities.
This program is able to sort motors by HP for optimization. The program is set up to be independent of
manufacturers' special conditions.
3
Generator Set Sizing
Select Generator Sizing from the Selection on the main menu and follow the screen instructions.
5 Sample Problems
In the first sample problem (TEST Study #1), 12 KVA and 12 KW are input as non-motor KVA
and KW loads. User wants to start a 150 HP motor and then a 50 HP motor with nameplate
information supplied (see the sample screens). Results show that user needs to select a generator
that meets the requirements specified at the end of the program output in terms of starting and
running KVA and KW. Studying one of the manufacturers' generator tables (Motor starting
capabilities of ONAN brushless, revolving field generator sets)(Table E – MOTOR STARTING
CAPABILITIES OF ONAN BRUSHLESS, REVOLVING FIELD GENERATOR SETS, page 27),
one can see that a 250DFM Generator with 864 Maximum Starting KVA and rated KVA of 312
meets our requirements.
In sample TEST Study #2, the user starts a 50 HP first and then the 150 HP motor. In this case, you
need to select a 300 DFM instead of a 250 DFM generator to meet program requirements.
6 Suggestions
Interlock motor control circuits and add approximately 10 seconds minimum delay between motor
starts.
Interlock sequence should be the same sequence as used in the program analysis.
Consider additional capacity for future requirements when making the generator set selection with
regard to a particular study.
Caution: If reduced voltage starters are used, ascertain with the manufacturer of the driven
equipment that the reduced starting torque applied will accelerate the load. Motor
damage could result if the torque of the motor is reduced to the point that the motor
cannot start accelerating.
The motors tabulated in the study represent the input sequence and should be checked to see if the
sequence corresponds to the operating conditions requirements.
If operating conditions permit, start largest motor first. If starting sequence is from the largest to the
smallest motor, the result will indicate the lowest KW and KVA rating for loads. If the starting
sequence is from the smallest to the largest, the result will indicate the largest KW and KVA rating
for loads.
Generator Set Sizing
7 Sample Screens
File consists of : New; Open…; Close; Save; Save As…; Output…; Print Preview…; Print…; Print
Setup…; Exit.
5
Generator Set Sizing
Look at the Reference Data Files from View where we have “Starters List” and “NEMA Motor Power”
specifications.
Generator Set Sizing
You may change, add, insert, delete, or modify the “Starters Lists”
You may add, delete, or modify the starter list and/or the “NEMA Motor Power” database.
7
Generator Set Sizing
7.3 Example 1
Under the File Menu, select New to start a new case. To validate the program, we created a file “TEST”.
Existing lighting, heating and resistive loads, in this example, add up to 12 KVA and 12 KW.
Generator Set Sizing
For this example, first we start a 150 HP motor and then a 50 HP motor; 460 voltage (L-L), 3-phase, class
F. Sequence Number 1 means the motor is the first in the sequence to start. The voltage is line-to-line
voltage. Nameplate Horsepower has a picklist library, press “Browser”. Phase is Single or Three. NEMA
Designator also has a picklist library.
9
Generator Set Sizing
At Nameplate Horse Power, press cursor to select a value from the motor library.
Starter Type has a picklist library.
Generator Set Sizing
At NEMA Designator field, press the cursor button to open the picklist library to select a design letter.
11
Generator Set Sizing
Select “Reports” from View to view the result from the notepad. DESIGNBASE output matches 100% the
"ONAN" results on page 23.
13
Generator Set Sizing
7.3 Example 2
Test study #2. Start a 50 HP motor, then a 150 HP motor. Initial system KW = 12 and KVA = 12.
Generator Set Sizing
“Results” screen.
“Reports” screen. DESIGNBASE output matches 100% the "ONAN" results on page 23.
15
Generator Set Sizing
7.3 Example 3
Output results for example 3. DESIGNBASE output matches 100% the "ONAN" results on page 23.
17
Generator Set Sizing
7.4 Example 4
Generator Set Sizing
Output results for example 4. DESIGNBASE output matches 100% the "ONAN" results on page 24.
19
Generator Set Sizing
7.5 Example 5
Generator Set Sizing
Output results for example 5. DESIGNBASE output matches 100% the "ONAN" results on page 24.
21
Generator Set Sizing
23
Generator Set Sizing
DESIGNBASE
GENERATOR SET SIZING PROGRAM
* Previous standard voltage was 220 Volts should be operated on 240 Volts whenever possible.
A 0 – 3.15 2.95
B 3.15 – 3.55 3.35
C 3.55 – 4.0 3.77
D 4.0 – 4.5 4.25
E 4.5 – 5.0 4.75
F 5.0 – 5.6 5.30
G 5.6 – 6.3 5.95
H 6.3 – 7.1 6.70
J 7.1 – 8.0 7.55
K 8.0 – 9.0 8.50
L 9.0 – 10.0 9.50
M 10.0 – 11.2 10.60
N 11.2 – 12.5 11.85
P 12.5 – 14.0 13.25
R 14.0 – 16.0 15.00
S 16.0 – 18.0 17.00
T 18.0 – 20.0 19.00
U 20.0 – 22.4 21.20
V 22.4 and up
25