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Volume V Issue 1
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%).
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.
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.
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
LINE
2 1
MOTOR
20 40 60 SPEED (% SYNCHRONOUS)
80
100
5 4 3 1 2
MOTOR
600 500 400 300 200 100 TORQUE 20 40 60 80 SPEED (% SYNCHRONOUS) 100 KVA
LINE
TYPICAL TORQUE AND KVA CURVES FOR SQUIRREL CAGE INDUCTION MOTORS
7 MOTOR
KVA
MOTOR
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
LINE
KVA
START: CLOSE 1-2-3 SECOND STEP: CLOSE 4-5-6 THIRD STEP: CLOSE 7-8-9
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TYPICAL TORQUE AND KVA CURVES FOR SQUIRREL CAGE INDUCTION MOTORS
LINE
KVA
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
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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.
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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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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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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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