DG Sizing of Generator

ELE CTRICAL DESIGN
PR OCEDURES BATTERY SIZING CALCULATIONS DTP-E-GEN-1006-00
ROLTA INDIA LIMITED
EDS ELECTRICAL DESIGN PROCEDURES

DG Sizing
Calculations
Calculations
DTP-E-GEN-1006-00
Revision History
Revision Revision Revision Department Head
Level Date Description (Approver)
This Document and all contained herein are proprietary of ROLTA INDIA LIMITED and is subjected to confidentiality restrictions
between ROTLA INDIA LIMITED and the Recipient. Copyright Reserved.
© Copyright 2008. Rolta India Issue Date: Page 1 of 23

Limited. All Rights Reserved.
Uncontrolled When Reproduced
ELE CTRICAL DESIGN
TABLE OF CONTENTS

ELE CTRICAL DESIGN
Subject Page no
8. EMPIRICAL FACTORS USED IN SIZING FOR MOTOR LOADS.................................................7
9. LOAD ANALYSIS...........................................................................................................................9
12 REQUIRED CALCULATION INPUTS........................................................................................15
13 REQUIRED CALCULATION OUTPUTS....................................................................................15
1. Purpose & Scope
DG sets are used under the following conditions:

1. As a primary source of power
a. Supplying isolated loads in the rural areas
b. Supplying essential loads in power / industrial / chemical plants.
2. As a backup to the main or grid supply
a. DG set operating in parallel with the grid
b. DG set sunning in isolation from grid supply for meeting the deficit or for some critical
loads.

ELE CTRICAL DESIGN
This design guide for Diesel – Generator Set (DG SET) covers the following aspects.
 Standard DG ratings and voltage levels
 Sizing of DG set
 Parallel operation with the grid
Neutral earthing
2. Applicability
This procedure is applicable to all projects.
3. References
ASME B15.1 Safety Standard for Mechanical Power Transmission Apparatus

ASME B31.1 Power Piping Code
IEEE 80 Guide for Safety in Substation Grounding
IEEE 112 Standard Test Procedure for Polyphase Induction Motors and
Generators IEEE 115 Test Procedure for Synchronous Machines
IEEE 43 Recommended Practice for Testing Insulation Resistance of Rotating Machinery
IEEE 1050 Guide for Instrumentation and Control Equipment Grounding in
Generating Stations
NEMA 250 Enclosures for Electrical Equipment (1000 Volts Maximum)
NEMA AB 1 Molded Case Circuit Breakers and Molded Case Switches
NEMA ICS-1 Industrial Controls and Systems
NEMA ICS-2 Industrial Control Devices, Controllers, and
Assemblies NEMA ICS-6 Enclosures for Industrial Controls and Systems
NEMA MG1 Motors and Generators (Including Rev. 1 and 2)
NEMA MG2 Safety Standard for Construction and Guide for Selection, Installation, and
Use of Electric Motors and Generators
4.0 DG Set Ratings & Voltages :

ELE CTRICAL DESIGN
DG sets upto 1000 KVA are rated for 415V and those above 1000 KVA are rated for 3.3 / 6.6 /
11 KV as per the requirement of primary distribution voltage in the plant.
Some of the typical ratings available in India are as follows :
415V : 10 / 25 / 50 / 75 / 100 / 125 / 150 / 200 / 250 / 300 / 400 / 500 / 650 / 750 / 800 / 1000 KVA
3.3/6.6/11 KV : 1460 / 2200 / 3000 / 5000 / 6500 / 8000 / 12000 KVA
5.0 Diesel Engine Speeds :
Diesel engine speed is normally classified into following three categories :
1. High Speed (above 750 RPM)

2. Medium Speed (above 300 RPM and upto 750 RPM)
3. Low Speed (upto 300 RPM)
When DG sets are used for continuous duty i.e. more than 6000 hours per year, it is recommended
that engine of either low speed or medium speed are selected for getting high service life. DG sets used for
emergency purpose can be of high speed type.
The above considerations are true only for the conventional loads like pump / fan motors, heaters,
lighting etc. However sizing of DG for feeding non-conventional loads like Arc Furnace and Rolling Mills is
very complex and not considered here.
6. DEFINATIONS:
1.1.1 System Performance

The power generating system shall conform to the following performance requirements:
1.1.1.1 Rating
Engine continuous horsepower shall be sufficient to deliver full rated generator set kW/kVA when
operated at rated rpm and equipped with all engine-mounted auxiliary loads.
1.1.1.2 Start Time and Load Acceptance
Upon receiving a start signal, the standby diesel generator shall be capable of starting automatically
without local attendance, reaching synchronous speed and rated voltage and frequency within 10 sec
and be ready to accept load to its rated capacity under at normal operating temperature, in accordance
with NFPA 110. The unit shall be capable of three consecutive starts without recharging. The standby
diesel generator set shall be capable of either manual or automatic start and, in either case, check
synchronization, automatically synchronize and close to either a live or dead bus.
1.1.1.3 Frequency regulation
Engine generator operation shall be isochronous, regulated to within the rated frequency ±0.25 % from
no load to full load.

ELE CTRICAL DESIGN
1.1.1.4 Voltage regulation

Generator terminal voltage shall be maintained at rated voltage ±0.5% for any steady state load between
no load and full load.
1.1.1.5 No load operation
It is required that the standby diesel generator be capable of operating at full speed, no load, for one
hour.
1.1.1.6 Transient Operation
When loaded in accordance with the above requirements, the transient voltage drop shall be limited such
that the generator voltage is not less than 80 percent of nominal voltage, and frequency is not less than
95 percent of nominal. In addition, the voltage at the generator shall recover to within 90 percent of
nominal voltage and the frequency to 98 percent of nominal within 2 sec after load application. During
recovery from transients caused by load application, or resulting from 100 percent load rejection, the
speed of the generator set shall not exceed nominal speed plus 75 percent of the difference between
nominal speed and the overspeed trip set point or 115 percent of nominal, whichever is lower.
1.1.1.7 Load Banks
Properly sized three-phase load bank, including associated switching equipment, shall be provided for
use during periodic exercising of the diesel generator.
7. GENERATOR LOADING:
Type of Electrical Load
Loads vary according to applications and it is useful to examine and classify their characteristics as
follows:
Passive Loads
Include heating, lighting and domestic type loads. Easily evaluated. Usually expressed in kW on
assumption of unity P.F. In sizing generating sets passive loads are usually treated as constant at the
specified kW.
Cage Induction Motors
The most common type of industrial load characterized by a high initial starting kVA at low P.F. and a
fairly high peak kW during run-up. Motor output usually expressed in kW so that:-
F.L. input kW = Rated kW output
Per Unit F.L. efficiency

ELE CTRICAL DESIGN
and F.L. input = F.L. input kW

kVA
F.L. power factor
If the motor output is expressed in HP:-
F.L. input kW = 0.746 X Rated HP Output
Per Unit F.L. efficiency
Columns (1) to (6) of Fig. 1 list typical full load performance figures for induction motors from 1.1 to
1000kW output.
The method used for starting squirrel cage motors is most important. The simplest method id D.O.L.
(direct-on-line) starting at full voltage and a typical motor would drawn an initial starting kVA of about
6.5 times the full load value, and a possible peak input kW during run-up of about 3.25 times full load
value. A motor supplied from a generating set and started in this way would probably produce serious
transient voltage dip problems and might, under some conditions, require an oversize engine to power the
run-up.
To reduce the demand on the supply during starting, cage motors frequently use different forms of reduced
voltage starting, the two most common being start-delta and auto-transformer starting. Both the initial
kVA and the peak kW are substantially reduced but the motor develops reduced torque, which prolongs
the run up time. Columns (7) to (12) of Fig. 1 show initial start kVA and peak input kW for typical cage.
motors with three methods of starting, D.O.L., auto-transformer with 75% tap and start-delta.
Slip ring Induction Motors
Used where high starting torque is required with a moderate starting current. Starting involves full voltage
applied to stator and series rotor resistance which is progressively cut out during run up. Starting kVA is
typically between 1.25 and 2.0 times rated input and starting power factor is high, typically 0.9 so that
generating set sizing considerations usually centre on engine power rather than transient voltage dip.
Columns (13) to (18) of Fig.1 show the kVA and kW input to slip ring motors during starting for three
starter settings 1.25, 1.5 and 2.0 times full load input. Rated load input is as for cage. motors and can be
taken from columns (1) to (6).
Rectifier and Similar Non-Linear Loads

Rectifier and thyristor type loads draw a current which is high in harmonics and when the supply is
obtained from a generating set the consequence distortion of the alternator voltage wave may be sufficient
to affect the operation of other equipment running from the same supply. Generator temperature and

ELE CTRICAL DESIGN
voltage control instability may also occur. Because of this, generators supplying non-linear loads should
be generously rated so that the kVA rating should be at least twice the full load kVA input to the rectifier
or thyristor.
Regenerative Loads
Cranes and hoists sometimes use electrical regeneration as a means of braking. The effect of returning
power to a generating set is to reduce the engine power requirement and produce an increase in speed.
Small levels of regeneration will be absorbed in the losses of the set but if it becomes appreciable, the
speed may rise to an unacceptable extent since the governor can have no effect in limiting the speed under
such conditions. To guard against this the net regenerated power should not exceed 20% to 25% of the
generating set kW rating, the lower figure for sets above 200 kW, the larger figure for small sets of say 20
kW rating. If this cannot be achieved then a ballast load should be connected across the generator
(activated by a reverse power relay) intermittently rated but capable of absorbing the maximum
regenerated kW’s.
Capacitive Loads
Although not normally a factor in sizing generating sets, mention should be made of the effect of
capacitive loads on generating sets. Such loads may result in an overall leading power factor condition
which tends to self excite the generator and in extreme cases may lead to excess terminal voltage which
the AVR cannot control. Special consideration must therefore be given to such cases.
8. EMPIRICAL FACTORS USED IN SIZING FOR MOTOR LOADS

8.1 “K” FACTOR
In the absence of Vendor Data the starting kVA for an induction motor may be estimated by the
application of the “K” factor to the full load kVA as shown in Fig.1. Thus:-
a. Initial starting kVA – F.L. kVA x K
For cage motors K will depend on the design of the motor and the method of starting. For D.O.L. starting,
K may vary between 5.0 and 7.5 a typical average value being 6.5 which may be used in the absence of an
actual figure. If reduced voltage starting is used then the K value will be reduced as the square of the
voltage so that:-
b.K for reduced voltage start = K for D.O.L. x V2
c. (where V is the reduced start voltage in P.U. of normal
volts). Thus for typical cage motors:-
V = Pu

ELE CTRICAL DESIGN
Starting Method Applied K Factor

Voltage
D.O.L. 1.0 6.5
Start-delta 0.58 2.2
Auto-transformer (60% tap) 0.60 2.3

Auto-transformer (75% tap) 0.75 3.6
For slip ring motors the starting kVA is restricted by the external starter resistance in the rotor
are usually determined by the starting torque requirements of the load.

a. A typical valve would lie between 1.25 and 2.0, but the Motor Vendor must advise.
8.2 "E" FACTOR

In starting a squirrel cage motor energy is required to accelerate the rotor and its coupled load from
standstill to normal running speed. If the load inertia is small, acceleration will be fast and only a small
amount of energy will be required, but for high inertia loads, acceleration will be prolonged and energy
input correspondingly increase.
The peak input kW is however the same.
Reduced voltage starting methods will reduce the power input during starting but will prolong the run up
time so that energy input for a given load inertia will be the same for all methods of starting including
D.O.L.
For lightly loaded motors and low inertia type loads the energy required during run up will be small and a
significant proportion could be contributed from the kinetic energy of the generating set rotating parts
assuming of course that the load on the generating set is sufficient to cause a significant drop in speed.
This means that under these conditions a satisfactory motor start can be made even though the peak kW
input to the motor is higher than the rated maximum output of the set. However, for high inertia loads the
kinetic energy available from the generating set would be too low to be a worthwhile contribution to the
total energy required to run the motor and its load up to speed and in these cases all the power must be
supplied from the engine which must therefore have sufficient peak load capability.
It can be shown that the peak kW input to a squirrel cage motor during run up is approximately half the
initial starting kVA and this can therefore be used to determine the engine power requirement for high
inertia loads. All cases can be estimated by the use of an empirical “E” factor so that:

ELE CTRICAL DESIGN
Effective peak kW = Start kVA x E
= FLkVA x K x E
a. The value given to E will depend on the application and particularly the motor load inertia. For
squirrel cage motors the maximum value will be 0.5 and other values can be found with the aid of
Fig.2.
For slip ring motors maximum kW occurs at the instance of starting and to allow for the high starting
power factor a value of 0.9 should be assigned to E for this class of machine. The same value can be used
for squirrel cage motors using special “soft start” techniques. where the run of characteristics obtained
from thyristor controls is not unlike that of a slip ring motor.
9. LOAD ANALYSIS
Figure 3 shows a tabulation, which is the analysis of a load comprising a number of separate elements. At
the top of the sheet the load elements are itemised in the order in which they will be applied to the
generating set. In the absence of other data the first item should be any passive load such as heating or
lighting followed by the dynamic loads (i.e. motors) starting with the machine which imposes the largest
starting load and working down in descending order. This is only a general rule and some re-arrangement
of order may prove advantageous after completing the first assessment.
The next lower section of the load analysis table lists the demand on the set as the successive load
elements are added.
At each application the initial kW is shown, the effective peak kW during run up of the motor and the final
kW after the load element is up to speed and running at its stated load. The sequence is repeated until all
the elements have been added as shown for the sample installation in Fig. 3. At the bottom of the table are
shown three key figures which will be used to determine the recommended plant.
Maximum Total Peak kW
This is the highest value in line reference 8 of the table and represents the maximum load the engine must
handle during the process of connecting the load elements.
Maximum Final kW
This is the final figure in line reference 9 of the table and is the expected total load when all the load is
connected and running at stated value. Normally this figure would represent the plant kW rating.
Maximum Starting kVA

This is the highest value in line reference 6 and is the highest suddenly applied kVA increment which the
alternator will experience. It must therefore be used to determine the alternator size in relation to transient
voltage dip limits.
© Copyright 2008. Rolta India Issue Date: Page 10 of

Limited. All Rights Reserved. 23
ELE CTRICAL DESIGN
After analysing the load as described above it is worth checking to see whether a different sequence of
applying the load elements would be beneficial. Clearly it cannot affect the final kW but it could result in a
lower maximum total peak kW which frequently determines engine size.
10. Sizing the Set

The Engine
The engine must meet two requirements. First it must be able to supply all the connected load elements
operating at their individual ratings for the required duration. Thus the “final kW” in Figure 3 must not
exceed the rating of the set, continuous or standby as appropriate.
The second requirement is that the engine must be able to develop sufficient power to meet the “maximum
total peak kW” also evaluated in Fig.8. If this is only slightly higher than the plant rating determined
above then it may make use of any engine short term reserve power which may be available (such as the
ten percent overload capacity for continuously rated sets). In many cases however, it will be substantially
greater in which case it will become the deciding factor in choosing the engine.
The special, but not uncommon, case of a generating set powering only a single large motor often results
in an engine peak power requirement out of all proportion to its continuous power rating. Since no other
loads are involved effective economy can sometimes be made using the frequency tied start method in
which the load motor and the generating set are run up together. The generating set controls for this,
although not complicated are not standard and would only be justified for the larger sets where the special
engineering costs could be absorbed.
The Generator
The generator must have a continuous (or standby if appropriate) rating comparable with the “final kW”
figure used in engine sizing. The load power factor is almost always taken to be 0.8 PF lagging but very
occasionally a different operating power factor may be specified and this must be taken into account when
choosing the generator.
A further requirement is that the generator must be able to handle the largest step kVA load without
excessive voltage dip which, in the absence of a prescribed figure should be taken as about 25 percent with
30 percent as an absolute maximum.
The three factors which determine transient voltage dip are:-
a. Alternator reactance
b.Load impedance
c. Load power factor
Considering a simple circuit comprising a generator represented by a voltage source and inductive
reactance (generator transient reactance) in series with the load impedance.
The simple generator is assumed to develop 1.0 Pu. volts at the terminals before the load
switch is closed. On closing the switch a current flows, limited by the load impedance and
the generator reactance in series so that part of the original 1.0 Pu volts is now dropped
across the generator reactance leaving a reduced voltage at the machine terminals.

ELE CTRICAL DESIGN
Let: E = Generated emf (= 1.0 Pu)
VT = Voltage at machine terminals
X = Pu transient reactance of generator
ZL = Pu. load impedance comprising in series
XL = Pu load reactance
RL = Pu load reactance
XL = Generator kVA x SIN (COS–1 )
Step kVA Load
RL = Generator kVA x COS 
Step kVA load
Total circuit
impedance
Z = ZL + X (added vectorially)
= RL + j (XL + X) = R2 L + (XL + X)2.Pu
Circuit prior to connecting transient load
I = E = 1.Pu
ZZ
Generator terminal voltage on connecting transient load,
VT = IZL.Pu

ELE CTRICAL DESIGN
Transient Voltage
Dip,
= E – VT = 1 – VT.Pu
The accurate estimate of running load of DG set can be made

considering individual motor rating , efficiency and power factor.
KVA = P * LF
PF * η * DF
Where,
KVA = Minimum DG capacity
P = Connected KW on DG
DF = Diversity Factor (>=1.0).
= Sum of Individual Max. Demands
Max. Demand on Power Station
The diversity factor is always greater than 1. If it is not

available the same can be assumed as 1.
LF = Load Factor (0.6 to 0.9)
Maximum real power consumed
= maximum real power that would be consumed
11.0 Performance of Generating Sets

Between the required maintenance intervals and under the site
ambient conditions. Generating set power outputs are defined in
the Codes by one of the following:
Continuous Power
This is the power that a generating set is capable of delivering

ELE CTRICAL DESIGN
continuously for an unlimited number of hours.

Prime Power
This the maximum power available during a variable power
sequence which may be run for an unlimited number of hours per
year and is the valve normally equal or greater than the calculated
emergency or standby loads. The permissable average power
during a 24 hour period shall not exceed a percentage, declared by
the supplier, of the Prime Power.
Limited Time Running Power
This is the maximum power that a generating set is capable of
delivering for up to 5000 hours per year of which a maximum of
300 hours is continuous. It is accepted that operation at this rating
will affect the life of the set.
Engine Governing Performance
Governors function by detecting a speed change and then
automatically adjusting the fuel supply to restore the speed to
normal. This means that except where load anticipatory devices
are used, governor operation must be preceded by an actual speed
change and for a large load change this speed change will usually
be considerable. BS7698, 4, recognizes several standards of diesel
engine governing, class G1 normally being chosen for generating
set applications. Governing performance can be defined by four
factors:
Steady State Speed Band
Total variation of speed under fixed load condition. For G1
governing, 1.0 percent for less than 25 percent load, 0.8 percent
for higher values.
Transient Speed Variation
Maximum deviation of speed following sudden load change
measured from mean steady state speed band before load change.
For G1 governing, 10 percent for 100 percent load removal, 10
percent for application of a stipulated load which is 100 percent
for naturally aspirated engines and a lesser figure for pressure
charged engines depending on the engine power (60 percent
would be typical for many engines).
Recovery Time
Measured from the point where speed departs from the initial
steady state speed band to the point when the speed returns to and

ELE CTRICAL DESIGN
remains within the new steady state speed band. For G1 governing
8 seconds maximum for the load changes defined for transient
speed variation limits.
Speed Droop
Speed change between zero and rated load. For G1 governing, 5 percent of rated speed.
Alternator Voltage Control Characteristics
The electrical load on a generating set is usually fluctuating, sometimes over wide variations and to
maintain a substantially constant output voltage an automatic, fast acting regulating system must be used.
In modern brushless alternators this is achieved by the use of a solid state AVR (automatic voltage
regulator) which adjusts the exciter field current to compensate for load, speed and temperature changes.
As in the case of the engine speed governor, a voltage change must occur before AVR action is initiated
and a measurable time elapse before the corrective process is complete.
BS.4999, part 40 (and other International Standards) cover voltage regulation and recognizes several
different grades. Grade VR2.23 is normally chosen for general purpose use in generating sets. Voltage
regulation performance can be defined by three factors.
Steady State Limits
Limits between which the terminal voltage will lie for any fixed load between no load and rated load at
rated power factor. For Grade VR2.23 steady state limits are 2.5 percent but limits of 2.0 percent or
even 1.0 percent are frequently specified for special application.
Transient Limits
Initial voltage change immediately following the sudden application of a specified low power factor load
or the sudden removal of rated load. For Grade VR2.23 the figure is 15 percent voltage dip for application
of 60 percent rated kVA at 0. To 0.4 lagging and 26 percent overshoot for removal of rated load at 0.8 p.f.
(Different transient limits are frequently specified for the application of specified loads such as starting of
motors).
Recovery Time
Time between point of sudden load application and the point at which the voltage returns to 97 percent of
rated voltage. For Grade VR2.23 maximum recovery time for load application specified in (b) above is 0.5
second.
Influence of Alternator Reactance on Transient Performance
Transient reactance of generators is effective whenever load changes occur. On applying a sudden load it
behaves as a series reactance, absorbing some of the generated voltage and

ELE CTRICAL DESIGN
causing the temporary voltage dip at the alternator terminals. Transient reactance is usually expressed in
per unit terms (although sometimes percentage) related to the rated load impedance. Thus a 0.25 Pu (or 25
percent) transient reactance would be numerically equal to a quarter of the impedance of the rated load
circuit. Since transient reactance is purely reactive whereas the load impedance usually comprises both
resistance and reactance it follows that the effect of transient reactance on voltage dip will depend on the
load power factor and zero power factor lagging will produce the greatest transient voltage dip for a given
load current.
12 REQUIRED CALCULATION INPUTS:
The following is a summary of the required inputs to the calculation to satisfy this procedure:-
a. Generator Bus Design
Loading kW and KVAR
(Motor)
kW and KVAR (Non Motor)
b.Profile for Load Changes
c. Permitted limits for voltage and frequency under steady state and transient conditions.
13 REQUIRED CALCULATION OUTPUTS:

Size of engine and generator required to meet all possible combination of load conditions while
remaining within the voltage and frequency limits.
FIG.1 – PERFORMANCE OF TYPICAL INDUCTION MOTORS
Maximum Input during starting and Run-up
Rated Typical Cage Motors Slip Ring Motors
Output Full Load Performance (E = 0.5) (E = 0.9)

ELE CTRICAL DESIGN
ELE CTRICAL DESIGN
Appro P.F P.U. Inpu Inpu D.O.L. Auto Start-

x HP . t t Transfor Delta
kW Eff K= K = 1.25 K = 1.5
kVA kW K = 3.6 K = 2.2
6.5
kVA kW kVA kW kVA kW kVA kW
(1) (2) (3) (4) (5) (6) kVA kW (9) (10) (11) (12) (13) (14) (15) (16)
1.1 1.5 0.8 0.75 1.81 1.47 (7) (8) 6.52 3.26 3.98 1.99 2.26 2.04 2.72 2.44
1
11.8 5.88
3 4 0.8 0.81 4.46 3.70 16.1 8.03 9.81 4.91 5.58 5.02 6.69 6.02
3
30 15
7.5 10 0.8 0.85 10.6 8.82 38.2 19.1 23.3 11.7 13.2 11.9 15.9 14.3
3
68.9 34.5
15 20 0.8 0.885 20.7 16.9 74.5 37.3 45.5 22.8 25.9 23.3 31.1 27.9
2
135 67.3
30 40 0.8 0.905 40.4 33.1 145 72.7 88.9 44.4 50.5 45.5 60.6 54.5
2
263 131
50 67 0.8 0.925 65.1 54.1 234 117 143 71.6 81.4 73.2 97.6 87.9
3
423 212
80 107 0.8 0.935 101 85.6 364 182 222 111 126 114 151 136
5
656 328
100 134 0.8 0.94 125 106 450 225 275 137 156 141 187 169
5
812 406
125 167 0.8 0.942 156 133 562 281 343 172 195 175 234 211
5
1014 507
150 200 0.8 0.945 185 159 666 333 407 203 231 208 277 250
6
1202 601
170 228 0.8 0.945 209 180 752 376 460 230 261 235 313 282
6
1358 679
200 268 0.8 0.945 246 212 886 443 541 271 307 277 369 332
6
1599 800
250 335 0.8 0.945 308 265 1109 554 678 339 385 346 462 416
6
2002 1001
300 400 0.8 0.945 373 317 1343 671 821 410 466 420 559 504
5
2424 1212
400 536 0.8 0.945 498 423 1793 896 1096 548 622 560 747 672
5
3237 1618

ELE CTRICAL DESIGN
500 670 0.8 0.945 630 529 4095 2047 2268 1134 1386 693 787 709 945 850
4
600 804 0.8 0.945 756 635 4914 2457 2722 1361 1663 832 945 850 1134 1021
4
800 1070 0.8 0.945 1020 847 6630 3315 3672 1836 2244 1122 1275 1147 1530 1377
3
1000 1340 0.8 0.945 1290 1058 8385 4192 4644 2322 2838 1419 1612 1451 1935 1741
2
.50 (a)
.45
(b)
.40
(c)
.35
10 20 50 100 200 500

ELE CTRICAL DESIGN
Description of Load Elements Rated kW Input kW Input kVA K
A Lighting and Heating 50 50 -
B SR Motor – Crusher – 2 x FLC Start 250 265 308 2.0
C SC Motor – Unloaded Compressor – Auto transf. 200 212` 246 3.6

75% Top
D SC Motor – Pump – DOL Start ) 7.5 8.8 10.6 6.5
E SC Motor – Fan – Y- Start ) Started together 15 16.9 20.7 2.2
F SC Motor – Fan – DOL Start ) 3.0 3.7 4.5 6.5
Load Elements
Line Ref A B C D E F G H
Initial kW (1) 0 50 315 527
F.L. kW (2) 50 265 212 8.8 16.9 3.7
Applied F.L. kVA (3) 50 308 246 10.6 20.7 4.5
Load Start K Factor (4) - 2.0 3.6 6.5 2.2 6.5
Start E Factor (5) - 0.9 0.38 0.45 0.45 0.4

Element
5
Start kVA (6) = (3) x (4) 50 616 886 69 46 29
Eff Peak kW (7) = (5) x (6) 50 554 336 31 20 13
Total Effective Peak kW (8) = (1) + (7) 50 604 651 591
Final kW (9) = (1) + (2) 50 315 52.7 556
Max value of Total Eff. Peak kW (max value of 651 Sizing Recommendation
line ref 8)
Cummins KTA 3891
Max value of Final kW (max value of line ref 9) 556

ELE CTRICAL DESIGN
Max value of Start kVA (max value of line ref 6) 886 577 kW Cont/635 kW O/L
with V/H2 AVR functions to handle 651 kW

peak.
Rating Class Cont K1 1.0 Alt Wdg type A L

 C ambient 30C . Service Volts 380 T
Low Reactance
Alternator Frame E7B S
M.ASL 1000 K2 952 Service HZ 50
G
Alt temp rise 100C (F) K3 1.0 Equiv. Max start 982 Cont kW = 620 S
kVA
Start kVA for 20% dip = 1023
Alt Equiv cont kW 529 Max % Transient 20
V.Dip
14. NEUTRAL EARTHING :
DG sets upto 500 KVA solidly earth system is recommended. The earthing is provided so as to minimise
the damage to stator winding in the event of an earth fault. If DG is envisaged to operate in parallel with the grid,
it is recommended to provide solidly earth system irrespective of KVA rating. In case of isolated operation of
DG set, for rating above 500 KVA, resistance earthing is considered for limiting the earth fault current to
maximum full load current of the DG set.
DG sets of 3.3 / 6.6 / 11 KV are always provided with resistance grounded system. The earth fault current
is limited to maximum full load current of the DG set.
The value of neutral resistor is given by
R = VL
√3 * IL
Where,
VL = Line to Line RMS voltage in Volts
IL = Rated Current in Amps

ELE CTRICAL DESIGN
R = Resistor value in Ohms

ELE CTRICAL DESIGN


DG Sizing of Generator

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ELE CTRICAL DESIGN

PR OCEDURES BATTERY SIZING CALCULATIONS DTP-E-GEN-1006-00

ROLTA INDIA LIMITED

EDS ELECTRICAL DESIGN PROCEDURES

© Copyright 2008. Rolta India Issue Date: Page 1 of 23

© Copyright 2008. Rolta India Issue Date: Page 2 of 23

1. Purpose & Scope

DG sets are used under the following conditions:

© Copyright 2008. Rolta India Issue Date: Page 3 of 23

This procedure is applicable to all projects.

ASME B15.1 Safety Standard for Mechanical Power Transmission Apparatus

4.0 DG Set Ratings & Voltages :

© Copyright 2008. Rolta India Issue Date: Page 4 of 23

11 KV as per the requirement of primary distribution voltage in the plant.

Some of the typical ratings available in India are as follows :

5.0 Diesel Engine Speeds :

Diesel engine speed is normally classified into following three categories :

1. High Speed (above 750 RPM)

1.1.1 System Performance

© Copyright 2008. Rolta India Issue Date: Page 5 of 23

1.1.1.4 Voltage regulation

F.L. input kW = Rated kW output

Per Unit F.L. efficiency

© Copyright 2008. Rolta India Issue Date: Page 6 of 23

and F.L. input = F.L. input kW

F.L. power factor

If the motor output is expressed in HP:-

F.L. input kW = 0.746 X Rated HP Output

Per Unit F.L. efficiency

Slip ring Induction Motors

Rectifier and Similar Non-Linear Loads

© Copyright 2008. Rolta India Issue Date: Page 7 of 23

8. EMPIRICAL FACTORS USED IN SIZING FOR MOTOR LOADS

© Copyright 2008. Rolta India Issue Date: Page 8 of 23

Starting Method Applied K Factor

D.O.L. 1.0 6.5

Start-delta 0.58 2.2

Auto-transformer (60% tap) 0.60 2.3

are usually determined by the starting torque requirements of the load.

8.2 "E" FACTOR

© Copyright 2008. Rolta India Issue Date: Page 9 of 23

Effective peak kW = Start kVA x E

Maximum Starting kVA

© Copyright 2008. Rolta India Issue Date: Page 10 of

10. Sizing the Set

© Copyright 2008. Rolta India Issue Date: Page 11 of 23

Let: E = Generated emf (= 1.0 Pu)

VT = Voltage at machine terminals

X = Pu transient reactance of generator

ZL = Pu. load impedance comprising in series

XL = Generator kVA x SIN (COS–1 )

Step kVA Load

RL = Generator kVA x COS 

Step kVA load

= RL + j (XL + X) = R2 L + (XL + X)2.Pu

Circuit prior to connecting transient load

Generator terminal voltage on connecting transient load,

© Copyright 2008. Rolta India Issue Date: Page 12 of 23

The accurate estimate of running load of DG set can be made