Optimizing Generator RPM for Standby Power Generation

White Paper

INTRODUCTION
From the introduction of reciprocating engines in generator set applications, the marketplace has continued to evolve and
change. One significant area of change has been the operating rpm of the engine. With improving engine technology
and better metallurgy, generator engine speed has steadily increased over the last 80 years. More recently, some
manufacturers have continued this trend by offering generator configurations operating at speeds greater than 1800 rpm.
In evaluating the value proposition of increased engine speed, various preconceptions are often encountered. The focus
of this article is to separate the myths from the facts and explore the advantages gained by optimizing engine speed for
standby power generation.

ENGINE RPM AND ALTERNATOR FREQUENCY

The AC frequency of the gensets electrical output is a function
of engine speed and alternator design. To achieve 60 Hz, the
alternator rotor must turn at a specific rpm for a given alternator
pole configuration. Figure 1 outlines the basic relationship
between engine rpm, alternator poles and typical applications.

MARKET TRENDS
Fifty years ago most generators operated at speeds below 900
rpm. Within the last thirty years, the diesel standby


Figure 1

generator market has moved from 1200 to 1800 rpm as engine outputs have increased. The prime power, natural gas driven
generator market has also migrated from 900 to 1200 rpm with some recent offerings at 1800 rpm.
These trends have also extended into the automotive style, spark-ignited engines serving applications up to 150 kW.
Historically operating at 1800 rpm, current technology is optimizing these engines for operation at 2300, 3000 and 3600
rpm. For operating speeds between 1800 and 3600 rpm, manufacturers utilize a simple gear reduction device between the
engine and a four pole alternator.
The trend toward increasing the operating speed of automotive derived engines provides multiple advantages, including
improved transient performance, less stress on engine bearings, increased power densities and reduced capital cost.

IMPROVING TRANSIENT PERFORMANCE

A generators engine must quickly respond to constantly changing loads to prevent the generator frequency from dipping
excessively. This transient performance characteristic is a function of the engines fuel system, amount of turbocharger
boost and the rotating kinetic energy of the genset. Diesel generators typically provide better response than spark-ignited
(natural gas) units due to the characteristics of the engines fuel system. This performance difference can be mitigated by
increasing the engine speed on spark-ignited units.
Most diesel generators, and some manufacturers automotive derived natural gas units, are turbocharged. When large load
changes occur, the turbocharger takes some time to spin-up, thus leaving the engine temporarily under-powered. In
recognition of this effect, some manufacturers have embraced raising engine speed instead of turbocharging for automotive
style engines. As engine speed increases, stored kinetic energy also increases at the square of speed. If engine speed is
doubled, stored energy increases by a factor of four.
Using these principles, generators operating at an ideal speed can significantly outperform comparable turbocharged natural
gas units and challenge the transient performance of diesel units. Figure 2 compares the block load transient performance
between an 8.1L turbocharged engine versus a higher rpm 6.8L configuration. By all measures, the transient performance
of the optimized engine outperforms the larger turbocharged configuration by a factor of two.

Figure 2

ENGINE LIFE: REDUCED BEARING STRESS

In todays competitive standby generator market, the challenge is to produce more power with smaller engines. For
diesel engines, the manufacturers accomplish this with increased turbo-boost: more air, more fuel and more power.
This common practice makes good engineering sense for high compression diesel engines that are designed for high
bearing loading. However, turbo charging spark-ignited, automotive engines raises concerns about the high stresses
placed on the engine bearings.

These concepts are intuitive to many of us based on our experiences using automobiles to tow heavy loads. The previous
comparison referenced a 6.8L engine. This is the same type of engine found in the F-250 pickup and the Excursion. If you
were towing a 35 foot boat up a steep grade requiring maximum power, would you:
A) Leave the engine in overdrive and crawl up the hill at 1800 rpm with the accelerator tight to the floor,
B) Stop at the local garage and add a turbocharger for more 1800 rpm engine torque, or
C) Increase engine rpm by coming out of overdrive?
The obvious answer is to increase engine rpm. For a given
power output, as engine speed increases, torque decreases
proportionately. That is significant because engines
produce torque by creating force on the pistons. That
force is carried by the main engine bearings, connecting
rod bearings, and wrist pin bearings. Turbocharging an
automotive engine dramatically increases torque and
significantly reduces engine life. Figure 3 compares
bearing loading for two different 125 kW configurations
using automotive-based engines.
The 8.1L engine, though 16% larger, experiences 45%
greater bearing stress than the higher rpm configuration. In
this operating speed range, the engine bearings tend to be
the limiting factor in engine lifenot piston ring to cylinder
wear. This is consistent with the design and power band of
an automotive engine.

Figure 3

INCREASING POWER DENSITY AND CUSTOMER VALUE

In addition to improving transient performance and
reducing bearing stress, optimizing rpm allows smaller
engines to comfortably produce more power. In sparkignited automotive engines, power increases of 50 to 100%
are common, while in diesel models power increases tend
to be a more modest 25%. The end result is generators that
are lighter, smaller, and a better value to the customer.

MYTH VERSUS FACTS

As a market evolves and adopts new technology, its not uncommon for confusion and misinformation to occur. Standby
power generation and the use of optimum rpm is no exception to this rule. The following points address some of this
confusion relative to improved rpm configurations.
Myth #1
The optimal engine speed for generator applications is 1800 rpm.
Though generally true for larger diesel configurations, smaller diesel and automotive style spark-ignited engines are not
suited for high power loads at 1800 rpm. Automotive derived engines are designed for significantly higher operating
speeds. The design intent of this classification of engines is not low speed, high torque power. Automotive engines are
designed to produce power through engine speed.

Myth #2
Optimizing engine speed above 1800 rpm reduces engine life and is unproven.
Standby power generation operates at power densities higher than most other applications. These extreme load levels stress
the engines bearings, making them the limiting factor in engine life. Increasing engine speed reduces bearing stress and
extends engine life. This practice of using the ideal generator rpm is a proven solution, with some manufacturers having
twenty-five years of in-field experience.
Myth #3
Increasing engine speed will reduce efficiencies, requiring
more fuel.
Engine efficiency is largely controlled by the engines
compression and air/fuel ratios. Full load fuel consumption
rates are comparable between automotive style engines
operating at an ideal speed and traditional 1800 rpm models
as shown in Figure 4.

Figure 4

Myth #4
Optimizing engine speed will result in a noisy generator.

Sound levels are also comparable between improved rpm generators and traditional models. Sound levels are significantly
affected by enclosure design and operating modes. The data presented in Figure 5 is typical of market norms for both
configurations. In addition to operating at the most favorable
engine speed for power and life, some manufacturers offer a
quiet test feature that reduces the sound levels an additional
10 dBA during no load weekly exercise.
After separating the facts from the myths, a strong argument
can be made for operating the engine at its most favorable
speed. Through this process, manufacturers are able to
improve transient frequency response, increase engine life
Figure 5
by reducing bearing loads, increase the generators power
density and offer more value to the customer. In addition to
these benefits, this technology is proven in the market, does not negatively impact full load fuel consumption and can be
implemented without increasing sound levels.
The main trend in standby power generation has been an ever-increasing power density level and the resulting increase in
customer value. This was historically accomplished by increasing engine speed. In todays market, engine operating speed
continues to be a key parameter that manufacturers optimize to meet the markets increasing demands for high performing,
reliable standby power solutions.

P.O. Box 8 Waukesha, WI 53187

1-888-GENERAC generac.com


Bulletin 0173720SBY / Printed in USA12.03, rev. 12.06