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Technical Topics

Volume V Issue 1

Starting Large Motors from an Onan Engine-Generator Set


Larry Bey Technical Marketing Specialist Jim Iverson Manager, Technical Sales
Synopsis: A common problem in sizing engine-generators is starting large motors (large relative to the generator set capacity). Typical problems include holding coils dropping out or chattering of the motor starter, and stalling of the motor due to insufficient torque for acceleration. The transient performance of an engine-generator set when starting large motors is a function of the complete generator set system, including the engine power available, the generator and its excitation system, and the energy stored in the rotating inertia of the generator set. Proper sizing for a successful start requires consideration of all these factors, more than just the generator only data.

Publication No. 900-0286A 1997 by Onan

Starting Large Motors from an Onan Engine-Generator


A common problem in sizing engine-generators is starting large motors (large relative to the generator set capacity). Large voltage and frequency deviations may occur if the generator set is not sized properly. Typical problems include holding coils dropping out or chattering of the motor starter, and stalling of the motor due to insufficient torque for acceleration. Other connected loads may be more sensitive to voltage and frequency deviations than the motor or motor starter. The rate of change in generator frequency can also be a problem for some static uninterruptible power supplies. If the load on the generator set consists of a single large motor, particularly motors requiring high starting torque, a number of problems may occur if the generator set does not have sufficient capacity. These problems may include sustained low voltage operation, extended load acceleration times, tripping of circuit breakers or motor protective devices, engine-generator protection shutdowns, etc. The engine generator set needs to be sized for both starting and running the loads, and it is very common for the load starting kW or kVA requirements to be the dominant factor in sizing. This is particularly true when a large percentage of the connected load is motors. Unlike a typical utility source, an engine-generator set is a limited power (kW) source, basically determined by the available engine horsepower. The transient performance of an enginegenerator set when starting large motors is a function of the complete generator set system, including the engine power available, the generator and its excitation system, and the energy stored in the rotating inertia of the generator set. Proper sizing for a successful start requires consideration of all these factors, more than just the generator only data. Be careful not to use generator manufacturers data for transient voltage dip which does not take into account the complete system, e.g., the engine performance. Onans Gensize 96 uses a database of representative test data on complete engine-generator set models for selection and prediction of transient performance.

Motor Starting Characteristics


Induction motors have starting characteristics as shown in Figure 1. During starting the motor draws approximately six times its full load current. This current causes a significant dip in output voltage from a high impedance source like an engine generator set until the motor reaches nearly full speed. Initially the starting power factor of the motor is very low which means that the engine power required is also low, but the power required by the motor peaks at about 80% of rated speed. The low power factor at motor standstill means that the correct calculation of generator locked rotor kVA capacity would use vector addition. The locked rotor kVA of the motor would be added vectorially to the running load kVA vector. However, since simple arithmetic addition will always give a larger result than vector addition, it will error on the conservative side. For a successful start the motor must develop greater torque than required by the load. The difference in torque between the motor and the load determines the rate of acceleration. Premium efficiency motors (Design E) have considerably higher starting currents than typical Design B, C , and D motors. For example, a 15 HP premium efficiency motor has a locked rotor kVA approximately 50% higher than a standard motor. The higher starting current must be taken into account to maintain specified transient voltage dip and recovery voltage of at least 90% of rated voltage during acceleration. If premium efficiency motors are powered by the generator set, there can be a significant increase in generator set size required to maintain voltage. The increase in size may be offset somewhat by the use of reduced voltage starting methods.

Figure One. Induction Motor Starting Characteristics - High inrush current causes the generator voltage to dip. Real power required from the engine peaks at about 80% of motor speed.

Voltage Dip
When starting a motor across the line with a generator set, the motor represents a low impedance load while at locked rotor or stalled condition, causing a high inrush current, typically six times the rated running current. The high inrush current causes the generator voltage to drop. This voltage dip is comprised of two main components, the transient voltage dip and the recovery voltage dip. A maximum transient voltage dip of 30% is important to maintain the holding force on coils and a recovery voltage of 90% is important to provide sufficient torque to accelerate the motor and its load. It is the RMS (root-mean-square) or effective voltage that provides the holding force and torque during starting. Onans Gensize 96 sizing software will not select an engine-generator set with less than 90% recovery voltage. The software does permit the user to adjust the transient voltage dip to the requirements of the connected load equipment.

Transient voltage dip may also have two components, the instantaneous voltage dip and possibly a roll off voltage dip. The instantaneous dip is a solely a function of the relative reactances of the generator and motor, and occurs instantaneously upon connecting the motor to the generator output. Because the instantaneous component of the transient voltage dip is the product of the motor starting current times the subtransient reactance of the generator (Ims x Xd), the benefit of a low reactance generator is less instantaneous voltage dip. The instantaneous voltage dip is predicted on curves published by the generator manufacturer. These voltage dip curves give an approximation of what might be expected for the instantaneous dip assuming frequency is constant, that is, with unlimited kilowatts available from the driver such as a test stand dynamometer fed by the utility. With actual engine-driven equipment, if the engine slows down due to a heavy starting kilowatt requirement, the transient voltage dip would include an additional dip as the torque matching characteristic of the voltage regulator rolls off excitation to help the engine recover speed. This is shown in Figure Two.

Figure Two. Transient Voltage Dip - Transient voltage dip includes a reactance drop and may or may not include a voltage roll-off depending on the engine speed. Following the transient voltage dip the regulator excitation system forces the field to recover voltage to rated.

Following the transient voltage dip, the generator excitation system detects the low voltage and responds by increasing excitation to recover to rated voltage. The excitation level depends on the field forcing capability of the excitation system. Field current cannot be changed instantaneously in response to load change. The regulator, exciter field, and main field all have time constants. The voltage regulator has a relatively fast response. The main field has a significantly slower response than the exciter field because it is many times larger. Field forcing is designed into all excitation system components to optimize recovery time. It must be enough to minimize recovery time, but not so much as to lead to instability (overshoot) or overcome the engine (which is a limited source of power). See Figure Two. Modern generators typically have the ability to force field current at about three times normal full load field current. Generators with permanent magnent generator (PMG) excitation have a constant excitation power source that is independent of the generator output. Onan recommends the use of PMG excitation for starting heavy motor loads, because a low voltage condition on the generator output would not affect the excitation power available for forcing the field. At the same time the motor begins to accelerate to rated speed, assuming that the motor develops enough torque. For induction motors, motor torque is directly proportional to the square of the applied voltage. The rate at which the motor accelerates to rated speed is a function of the difference between the torque the motor develops and the torque requirements of the load. In order to avoid problems with excessive acceleration time or possibly stalling the motor, it is important for the generator to recover to rated voltage as quickly as possible. The manner in which the generator voltage recovers is a function of several factors including the relative sizes of the generator, the motor, the kilowatt capacity of the engine, and the generator excitation forcing capability. If the excitation system responds too fast and too stiff the generator can actually overload the engine when starting large motors. Depending on the severity of the load, several cycles to a few seconds later, the generator recovers to rated voltage. The maximum locked rotor kVA capability of a generator, while still maintaining 90% of rated voltage is derived from its sustained overload characteristic, shown in Figure Three. The characteristic is graphed based on short circuit testing done at near zero power factor. Since the motors locked rotor kVA is expressed based on full voltage starting it is necessary to correct the generator kVA at 90% voltage to kVA at 100% voltage. To do this graphically a line is drawn from zero through the overload characteristic curve at 90% voltage. The line is extended to the intersection at 100% voltage. From that intersection a vertical line is dropped down to read the maximum motor starting kVA that corresponds to the motors locked rotor kVA. A typical kVA overload capability is 2.5 to 3.0 times the generators rating.

100 90 80 % Rated Volts 70 60 50 40 30 20 10 0 1.0 2.0 kVA or Amperes PU 3.0 kVA at 100% Voltage

Figure Three. Generator Overload Characteristic - Maximum motor starting kVA at 90% recovery voltage corrected to motor nameplate voltage (100%).

Real Power and Frequency Dip


If I can start it, I can run it. Thats the way a senior engineer once summed up sizing an engine-generator set for a motor load. He was making the point that real engine power is what starts and accelerates motors, and that this starting kW (SkW) requirement often determines what size the engine-generator needs to be. The starting kW requirement of the motor can be as high as 3 times its running kW requirement. It is particularly important when starting large motors that the engine has sufficient power (SkW) to meet this demand, or the motor may not start successfully. Any engine preload subtracts from the available engine power. If the engine cannot develop sufficient power, the motor being started will rotate at a low speed determined by the balance between the power developed by the engine and the power required by the motor. The stored energy in the rotating inertia of the engine generator set can overcome the maximum power required by motors that are small compared to the engine, but on larger motors the engine may slow significantly during the momentary overload or a generator set protective device may operate. Onan generator sets include a torque matching voltage regulator function which senses the slowing down of an overloaded engine and rolls off excitation power to reduce output voltage enough to allow the engine to recover. Since power is proportional to the square of the voltage, a small reduction in voltage will assist the engine in picking up the kilowatt load.

Motor Moment of Inertia


The moment of inertia for a rotating mass is its resistance to acceleration. To start the motor and its load rotating this inertia must be overcome by an accelerating torque which translates to engine power (SkW). The load connected to the motor shaft has its moment of inertia and in practical situations for specific equipment this may or may not be available information. Fortunately, for the purpose of sizing the engine-generator set, or more specifically to determine the engine power needed to start and accelerate a rotating motor load, the motor load moment of inertia need only be broadly categorized as low or high inertia. High inertia loads are characterized by high breakaway torque requiring prolonged acceleration times and/or pulsating or unbalanced loads. Low inertia loads are characterized by low starting

torque at standstill, increasing as motor speed increases resulting in high acceleration to rated speed. High inertia loads are harder to start than low inertia loads. Examples of high inertia loads include: Single and multi-cylinder pumps Single and multi-cylinder compressors Crushers Hydraulic Elevators without unloading valves

Examples of low inertia loads include: Fans, Centrifugal and Blower Rotary Compressors Pumps, Rotary and Centrifugal Motor-Generator Elevators

Note: Pumps starting into high head pressure, large diameter fans or fans starting into high restriction should be classified as high inertia loads. If the motors are driving low inertia loads with low starting torque requirements, Gensize will multiply SkW by a factor of 0.6 because these loads accelerate so quickly that the engines inertia provides sufficient energy to maintain near rated speed until the motor achieves rated speed and running kilowatts.

Power Factor Correction


Loads that include power factor correction or filters for power quality improvement should not be applied to a generator set operating at light load levels. The capacitive elements of these loads can cause the voltage of a generator set to rise uncontrollably at light load levels. Power factor correction capacitors for large motors should either be switched with the motor or be connected to the utility side of the transfer switch, not the load side.

Regenerative Loads
Loads such as elevators, cranes and hoists often rely on the capability of the source to absorb power during certain sequences of operation, typically for braking purposes. Since the utility is essentially an infinite power source serving diverse loads, this is not a problem when operating from utility power. A generator set, however, is a limited power source and has limited capability to absorb power, especially if no other loads are connected. The regenerative power capability of a generator set is information that is available from the manufacturer. A typical regenerative capability is about 15% of the generator set rating. If the regenerative power of the load exceeds the capacity of the generator set, the generator set may overspeed and shutdown on overspeed protection. The overspeed limit of a generator set rated at 1800 RPM is usually about 2100 +/- 50 RPM. Applications that are most likely to be a problem are where an elevator is the major load on the generator set. Generally, the regeneration problem can be solved by adding loads which can absorb the regenerative power. For example, transfer the lighting load to the generator first before transferring the elevator.

Running Surge Voltage Dip


Once all the loads on the generator set have been started, some of those loads may cycle ON and OFF when called on by an automatic control, such as an air conditioner or an elevator. If there are motors that cycle, a running surge voltage dip should be calculated. The worst case condition would be when all cyclical loads start simultaneously with the rest of the connected load running. Taking cyclical loads into account could significantly increase the size of the required generator set depending on the required transient performance and could invalidate the process of placing loads in a step starting sequence. The worst case calculation for running surge voltage dip starts with the total preload in running kW and kVA and adds the total starting kW and kVA of all of the cyclical loads. Onans Gensize 96 asks the user to specify a maximum running surge voltage dip and to select which loads cycle ON and OFF. With this information the software will calculate the running surge voltage dip and select an appropriate generator set.

Reduced Voltage Starting Methods


Although voltage dip often causes various problems, a controlled reduction in voltage at the motor terminals can be beneficial when it is used to reduce the starting kVA of a motor in applications where the reduced motor torque is acceptable. It is important to determine that an acceptable level of motor torque is achieved. If not, loads will be slow to accelerate or may fail to reach full speed and motor damage can result. Reducing motor starting kVA can reduce the size of the generator set required, lessen the voltage dip and provide a softer start for the motor loads. All of the following reduced voltage starting methods are included in the Gensize 96 program.

A Comparison of Motor Starting Methods:


Table 1 compares the effects of full voltage, autotransformer and resistor starting on a 50 horsepower, Code G motor. As can be seen, autotransformer starting requires less motor starting capacity from the generator set.

TABLE 1. REDUCED VOLTAGE MOTOR STARTING COMPARISON


TYPE OF STARTER AUTOTRANSFORMER % of applied voltage (tap) % of full voltage Starting kVA Starting kW Run kVA Run kW 65 42 124 47 46 42 RESISTOR 42 42 124 106 46 42 FULL VOLTAGE 100 100 295 110 46 42

Full Voltage Motor Starting


Full voltage, acrosstheline starting is typical unless it is necessary to reduce motor starting kVA because of the limited capacity of the generator set or to limit voltage dip during motor

starting. There is no limit to the HP, size, voltage or type of motor. This method is most common because of its simplicity, reliability and initial cost. Note on the kVA and torque curves that starting kVA remains fairly constant until the motor almost reaches full speed. Also note that kW peaks at about 300 percent of rated near 80 percent of synchronous speed.
MOTOR STARTING DIAGRAM TYPICAL TORQUE AND KVA CURVES FOR SQUIRREL CAGE INDUCTION MOTORS

kVA & TORQUE (% F. L.)

600 500 400 300 200 100 TORQUE KVA

LINE

2 1

MOTOR

START: CLOSE 1-2-3 RUN: NO CHANGE

20 40 60 SPEED (% SYNCHRONOUS)

80

100

Autotransformer Motor Starting, Open Transition


The autotransformer is in the circuit only during starting to reduce voltage to the motor. The opening of the circuit during transition can cause severe transients. Open transition switching of reduced voltage starters should be avoided in generator set applications, especially when the motors are not brought up to full speed at the time of transition. The reason for this is that the motor slows down and is then out of synchronization during the switching transition. The result is similar to paralleling generator sets out of phase. The kVA drawn immediately after switching can exceed starting kVA. Also note that the starting power factor is lower when an autotransformer is used.
MOTOR STARTING DIAGRAM 7 TYPICAL TORQUE AND KVA CURVES FOR SQUIRREL CAGE INDUCTION MOTORS

5 4 3 1 2

MOTOR

kVA & TORQUE (% F. L.)

600 500 400 300 200 100 TORQUE 20 40 60 80 SPEED (% SYNCHRONOUS) 100 KVA

LINE

START: CLOSE 2-3-5-6-7 RUN: OPEN 2-3-5-6-7; CLOSE 1-4-8

Autotransformer Motor Starting, Closed Transition


The circuit is not interrupted during starting. During transfer, part of the autotransformer winding remains in the circuit as a series reactor with the motor windings. Closed transition is preferred over open transition because of less electrical disturbance. The switching, however, is more expensive and complex due to three elements. It is the most commonly used reduced voltage starting method for large motors with low load torque requirements, such as MG sets, sewage lift pumps and chillers. The principle advantage is more torque per current than with other reduced voltage starting methods. Operation can be automatic and/or remote. Also note that the starting power factor is lower when an autotransformer is used.

MOTOR STARTING DIAGRAM 5 4 LI N E 3 2 6 kV 600 A &500 T O400 R Q300 U E 200 (% 100 F.

TYPICAL TORQUE AND KVA CURVES FOR SQUIRREL CAGE INDUCTION MOTORS

7 MOTOR

KVA

TORQUE 20 40 60 80 SPEED (% SYNCHRONOUS) 100

START: CLOSE 6-7-2-3-4 TRANSFER: OPEN 6-7 RUN: CLOSE 1-5

Reactor Motor Starting, Closed Transition


Reactor starting has the advantage of simplicity and closed transition, but results in lower starting torque per kVA than with autotransformer starting. Relative torque, however, improves as the motor accelerates. Reactor starting is generally not used except for large, highvoltage or highcurrent motors. The reactors must be sized by HP and voltage and may have limited availability. Typically, reactor starting costs more than autotransformer starting for smaller motors, but is simpler and less expensive for larger motors. Starting power factor is exceptionally low. Reactor starting allows a smooth start with almost no observable disturbance on transition and is well suited for applications such as centrifugal pumps or fans.
MOTOR STARTING DIAGRAM 6 3 5 TYPICAL TORQUE AND KVA CURVES FOR SQUIRREL CAGE INDUCTION MOTORS 600 500 400 300 200 100 TORQUE 20 40 60 80 SPEED (% SYNCHRONOUS) 100 KVA

2 4 1 START: CLOSE 1-2-3 RUN: CLOSE 4-5-6

MOTOR

Resistor Motor Starting, Closed Transition


Resistor starting is occasionally used for smaller motors where several steps of starting are required and no opening of motor circuits between steps is allowed. Also available as a stepless transition starter which provides a smoother start. Resistor starting is usually the least expensive with smaller motors. Loads accelerate faster because the voltage increases with a decrease in current. Resistor starting has a high starting power factor, so it may actually increase the size of the generator set.

kVA & TORQUE (% F. L.)

LINE

MOTOR STARTING DIAGRAM 6 3 5 8 MOTOR 9 600 500 400 300 200 100

TYPICAL TORQUE AND KVA CURVES FOR SQUIRREL CAGE INDUCTION MOTORS

2 4 1 7

kVA & TORQUE (% F. L.)

LINE

KVA

START: CLOSE 1-2-3 SECOND STEP: CLOSE 4-5-6 THIRD STEP: CLOSE 7-8-9

TORQUE 20 40 60 80 SPEED (% SYNCHRONOUS) 100

StarDelta Motor Starting, Open Transition


StarDelta starting requires no autotransformer, reactor or resistor. The motor starts star connected and runs deltaconnected. This starting method is becoming more popular where low starting torques are acceptable. It has the following disadvantages: 1. Open transition. Closed transition is available at extra cost. 2. Low torque. 3. No advantage when the motor is powered by a generator set unless the motor reaches synchronous speed before switching. In applications where the motor does not reach synchronous speed, the generator set must be sized to meet the surge.
MOTOR STARTING DIAGRAM 3 2 LINE 1 8 7 MOTOR 4 5 6 600 500 400 300 200 100 TORQUE 20 40 60 80 SPEED (% SYNCHRONOUS) 100 KVA TYPICAL TORQUE AND KVA CURVES FOR SQUIRREL CAGE INDUCTION MOTORS kV A & T O R Q U E (% F. L.)

START: CLOSE 1-2-3-4-5-6 RUN: OPEN 4-5-6; CLOSE 7-8-9

Part Winding Motor Starting, Closed Transition


Part winding starting is less expensive because it requires no autotransformer, reactor or resistor and uses simple switching. Available in two or more starting steps depending on size, speed and voltage of motor. Automatically provides closed transition. First, one winding is connected to the line; after a time interval, the second winding is paralleled with the first. Starting torque is low and is fixed by the motor manufacturer. The purpose of part winding is not to reduce starting current but to provide starting current in smaller increments. There is no advantage to this method if the motor is powered by a generator set unless the motor can reach synchronous speed before transition to the line.

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MOTOR STARTING DIAGRAM 3 600 500 400 300 200 100

TYPICAL TORQUE AND KVA CURVES FOR SQUIRREL CAGE INDUCTION MOTORS

2 1 MOTOR 6 5 4 START: CLOSE 1-2-3 RUN: CLOSE 4-5-6

kVA & TORQUE (% F. L.)

LINE

KVA

TORQUE 20 40 60 80 SPEED (% SYNCHRONOUS) 100

Wound Rotor Motor Starting


A wound rotor motor can have the same starting torque as a squirrel cage motor but with less current. It differs from squirrel cage motors only in the rotor. A squirrel cage motor has short circuit bars, whereas a wound rotor motor has windings, usually threephase. Starting current, torque and speed characteristics can be changed by connecting the proper amount of external resistance into the rotor. Usually, wound rotor motors are adjusted so that the starting kVA is about 1.5 times running kVA. This is the easiest type of motor for a generator set to start.
MOTOR STARTING DIAGRAM 3 600 500 400 300 200 100 TORQUE 20 40 60 80 SPEED (% SYNCHRONOUS) 100 KVA TYPICAL TORQUE AND KVA CURVES FOR WOUND ROTOR MOTORS

2 1 MOTOR ROTOR 4 5 6 7 8 9 START: CLOSE 1-2-3 STEP #1: CLOSE 4-5 STEP #2: cLOSE 6-7 RUN: CLOSE 4-5-6

RESISTORS

Solid-State Starters
Solid-state starters can adjust the starting torque, acceleration ramp time, and current limit for a controlled acceleration of the mechanical load while starting motors. For the purpose of sizing the generator set, the current limit adjustment reduces the inrush current and may be used to reduce the starting kW and kVA requirement on the generator. The range of available current limit settings are typically from 150 to 600% of full load current. A 600% current limit setting would be sized just the same as across-the-line starting. A 300% current limit setting would reduce SkW and SkVA by 50%. Use of the current limit setting also reduces the motor torque available to the load. The sequence of operation of a solid-state starter is shown in Figure 4. From standstill the starter applies an initial voltage to provide sufficient torque to begin to rotate the motor. Typically this voltage (torque) is adjustable from 0 to 100%, with a typical setting of 60% or at the minimum effective starting torque. The acceleration ramp time is adjusted to control the time it takes the starter to reach current limit. A typical range of ramp time adjustment is from 0 to 60 seconds. The setting is based on the desired time to accelerate the mechanical load. The current limit setting caps the inrush current until the motor comes up to full speed. From a generator sizing perspective, an extended acceleration ramp time and a low current limit

kVA & TORQUE (% F. L.)

LINE

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setting (if also appropriate for the motor and the mechanical load) would have the minimum impact on voltage and frequency excursions.

CURRENT LIMIT
MP RA ION AT R LE CE AC

CURRENT

INITIAL TORQUE

RUN CURRENT

TIME
Figure 4. Solid-state Starter Sequence of Operation - The initial torque, acceleration time, and current limit may be adjusted to provide a smooth start for the load.

Solid-state starters use SCRs and are a non-linear load that will cause voltage distortion. To compensate for this distortion the generator capacity should be increased. The recommended generator capacity required is two times the running kilowatt load, except where an automatic bypass is used. If the solid-state starter is equipped with an automatic bypass, the SCRs are only in the circuit during starting. Once the motor is running the bypass contactor closes and shunts the SCRs. In this case, the voltage distortion may be ignored during starting and there would be no additional generator capacity required. Gensize 96, Version 2.0, includes a selection for automatic bypass with solid-state starters.

Variable Frequency Drives


All variable frequency drives are current limiting and reduce both starting kW and kVA. The current drawn by these drives is non-linear harmonic currents, which cause a distorted voltage drop across the reactance of the generator. Since VFDs are non-linear an additional generator capacity sizing factor needs to be used to keep voltage distortion to a reasonable level, 15% total harmonic distortion or less. For six-pulse VFDs a typical generator sizing factor would be two times the running kW of the drive. The increase in size of the generator for the non-linear current will more than offset any reduction in starting kW and kVA. If the VFD is the pulse width modulated type, or includes an input filter to limit current distortion to less than 10%, then the additional sizing factor may be reduced to 1.4 times the running kW of the drive. Gensize 96, Version 2.0, includes a selection for PWM drives with input filters.

Sizing examples using Gensize 96:


Sizing the engine-generator set may be done with manual calculations using a worksheet available in Onan Application manual T-030 or with GenSize 96 software. The basic process is the same. It is always best to use actual data if known, otherwise one advantage of GenSize

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96 is that much of the required information on typical load characteristics is available as default information. One commonly used approach is to assume that all connected loads will be started in a single step. This assumption will result in the most conservative (largest) generator set selection. Unless something has been done, such as multiple transfer switches with staggered time delays or a step load controller, then a single step load should be used for sizing purposes. However, once all of the loads have been brought up on line with the generator set, the load equipment may be frequently stopped and started by automatic controls. In such cases, the generator set will have to be sized to start the largest motor last, with all other connected loads on line. Following are five sizing examples. The first three examples have been selected to show the effect on recommended generator set size of transient voltage dip specifications and autotransformer reduced voltage starting. The last two examples have been selected to show the effect of multiple steps compared to a single step when starting several large motors. Example 1. 200 HP motor across-the-line with 10% transient voltage dip. Refer to Figures Five and Six. In this example the specification for no more than 10% transient voltage dip when starting a large (200 HP) motor across the line results in a selection of a 1100 kW generator set with an oversized 80 degree C rated rise generator. The running load on this generator set is only 14% of rated standby kilowatts which is well below the 30% recommended minimum. This would not be a good selection. If used this diesel engine would probably experience problems with wet stacking, carboning, oil diluted with fuel, etc.

Figure Five. 200 HP Motor Load Characteristics - The motor is started across the line and is low inertia.

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Figure Six. Example #1 Generator Set Selection - With 10% transient voltage dip a 1100 kW generator would be required.

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Example 2: Figure Seven. A 200 HP motor across-the-line with 30% transient voltage dip. In this example starting the same motor as in the first example, but allowing the transient voltage dip to be 30% maximum (29% estimated actual), the generator set selection goes down to a 200 kW set with a 125 degree C rated rise generator running at 81% of rated load. This would be a reasonable selection.

Figure Seven. Example #2 Generator Set Selection - With 30% transient voltage dip allowed, a 200 kW generator set is selected.

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Example 3: Figures Eight and Nine. 200 HP motor with autotransformer start and 30% transient voltage dip. In this example use of the autotransformer reduced voltage starting at the 65% tap further reduces the generator set selection to a 175 kW with a 125 degree C rated rise generator. The estimated actual transient voltage dip is down to 18% and the running load is up to 93% of rated. If no future load increases are expected, this would also be a reasonable selection.

Figure Eight. 200 HP Motor Load Characteristics - The motor is started with autotransformer starter at 65% tap and is low inertia.

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Figure Nine. Example #3 Generator Set Selection - With autotransformer starter, a 175 kW generator set is selected.

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Example 4: Figure Ten. Three 200 HP high inertia motors started across-the-line in a single step with 30% transient voltage dip allowed. Refer to Figure Ten. In this example a selection is made for a 800 kW standby rated generator set running at 61% of rated load.

Figure Ten. Three 200 HP motors started in a single step - The starting kilowatts (SkW) required results in selection of an 800 kW standby generator set.

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Example 5: Figure Eleven and Twelve. Three 200 HP motors in three steps. A step start sequence is accomplished using three automatic transfer switches with staggered time delays, or other step sequence controller. Use of three steps reduces the generator set selection to a 500 kW model.

Figure Eleven. Three 200 Hp motors started in three steps - Using three step starting sequence reduces the size of the generator set from 800 kW to 500kW standby.

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The running load of 488 kW, which conservatively assumes that the motors are loaded to nameplate rating, equals about 97% of the generator standby rating. The generator set is rated to carry this load in applications within the standby rating definition. Since the margin, if any, between motor nameplate power and the actual load on the motor is seldom actually known, a more definite margin may be added by stepping up a size to the 600 kW model. Gensize 96 allows the user to select models as shown in Figure Twelve. With a nameplate running kW of 488, the 600 kW generator set would run at 81% of rating or less.

Figure Twelve. Example #5 Generator Set Selection - Stepped up a size to the 600 kW model.

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Gensize 96 Glossary of Terms


GkW - Generator capacity provided to compensate for non-linear distortion, usually equal to RkW times a factor for the type of non-linear load. Max SkVA - Maximum Surge Kilovolt-amperes, the highest kilovolt-ampere load in any load step. Max SkVA Req. - Maximum Surge Kilovolt-amperes Required, the highest total of any surge kVA load added to the previously running kilovolt-ampere load. Max SkW - Maximum Surge Kilowatts, the largest block of kilowatt load in any load step. Max SkW Req. - Maximum Surge Kilowatts Required, the highest total of any surge kW load added to the previously running kilowatt load. RAmps - The total running amperes for a step. Reduced Max SkVA Req. - The Max SkVA Req. times a multiplier to compensate for reduced voltage. Must be less than or equal to the generator set Max kVA. Reduced Max SkW Req. - The Max SkW Req. times a multiplier to compensate for reduced voltage. Must be less than or equal to the generator set Site rated Max SkW. RkVA - Running Kilovolt-amperes, the running load. RkW - Running Kilowatts, the running load. RPF - Running power factor is the load power factor when the load is running at rated steady state conditions. RSkVA - The running surge kilovolt-amperes, the total surge kVA of all cyclic loads, added to any welder loads, and medical imaging loads. RSkVA Req. - The running surge kilovolt-amperes required, the highest total of any running surge kW load added to the previously running kilowatt load. RSkW - The running surge kilowatts, the total surge kW of all cyclic loads, added to any welder loads, and medical imaging loads. RSkW Req. - The running surge kilowatts required, the highest total of any running surge kW load added to the previously running kilowatt load. SPF - Starting power factor is the power factor of the load at the time it is initially energized or started. This is a particularly important parameter for motor loads which exhibit a low power factor during locked rotor conditions, causing a high inrush kVA (SkVA) during starting.

Summary
Sizing an engine-generator set for starting large motors requires an understanding of motor characteristics, starting methods, and the transient performance of the engine-generator during motor starting. Because the engine-generator set is a limited power source both in kW and kVA, voltage and frequency excursions will occur when starting motors. A properly sized engine generator set will keep the voltage and frequency excursions within reasonable limits without oversizing the machine. Use Gensize 96 to make the sizing problem easier and the resulting recommendation more accurate.

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About the Authors


Jim Iverson Manager, Technical Sales has been with Onan since 1976. He has a Masters in Engineering Science, Bachelors in Electrical Engineering. Jim spent 7 years at General Electric and 2 years at Electric Machinery before joining Onan. While at Onan, he managed Transfer Switch Design, Systems Engineering and Switchgear and Controls. Current responsibilities are to provide technical direction to the Commercial Marketing and Sales Department, participate in domestic codes and standards development, sales and service training, technical input for and review of all published literature, published papers on relevant industry topics. Lawrence A. Bey Senior Technical Marketing Specialist and a 1978 University of Minnesota Graduate. Larry has been an Onan employee from 1978 to the present, spending 7 years in Engineering, and 11 years in Marketing and Sales. He represents Onan on Technical Committees of the National Fire Protection Association for NFPA 110 Emergency and Standby Power Systems and NFPA 99 Essential Electrical Systems for Health Care Facilities. Larry is active with National electrical Manufacturers Association (NEMA) on Motor and Generator Subcommittee and the Automatic Transfer Switch Equipment Subcommittee. He is a member of the International Association of Electrical Inspectors.

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See your distributor for more information.

Onan Corporation 1400 73rd Avenue N.E. Minneapolis, MN 55432 612-574-5000 Fax: 612-574-8087
Onan and PowerCommand are registered trademarks of Onan Corporation
Cummins is a registered trademark of Cummins Engine Company

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