Emergency generator sizing and motor starting analysis

Abstract—This paper investigates the preliminary sizing of
generator set to design electrical system at the early phase of a
project, dynamic behavior of generator-unit, as well as induction
motors, during start-up of the induction motor drives fed from
emergency generator unit. The information in this paper simplifies
generator set selection and eliminates common errors in selection. It
covers load estimation, step loading capacity test, transient analysis
for the emergency generator set. The dynamic behavior of the
generator-unit, power, power factor, voltage, during Direct-on-Line
start-up of the induction motor drives fed from stand alone gene-set is
also discussed. It is important to ensure that plant generators operate
safely and consistently, power system studies are required at the
planning and conceptual design stage of the project. The most widely
recognized and studied effect of motor starting is the voltage dip that
is experienced throughout an industrial power system as the direct
online result of starting large motors. Generator step loading
capability and transient voltage dip during starting of largest motor is
ensured with the help of Electrical Transient Analyzer Program
(ETAP).
Keywords—Sizing, induction motor starting, load estimation,
Transient Analyzer Program (ETAP).
I. INTRODUCTION
T is extremely important to initially select the correct
generator set due to high initial cost of generator sets, the
installation, and other equipment involved [1]. The generator
rating is not necessarily to be just sum of the loads if some
non-linear loads present. Conventionally that may be taken
care by margin factor but to determine a cost effective as well
as project required rating of generator, effective loads on
generator must be calculated properly to avoid generator over
sizing [2], [3].
Dynamic conditions of generator-unit are interesting in case
of smaller, often isolated electrical grids. Induction machine
play a very important role in the industrial applications and a
significant number of induction motors are used at critical
points of on board processes [4]. As compared to a utility bus
feed, an on-site Gene-set is a limited source of horsepower,
from the engine, and kVA from the generator. Thus, a gene-set
must be large enough to start as well as run connected motor
loads. At start, an induction motor draws heavy surge of
current from the power system that in turn causes a dip in
system voltage [5]. Flicker can create a problem to both the
generator and the connected loads. The basic requirement for
studying starting analysis of Induction motor are the starting
Mukesh Kumar Kirar, assistant professor, Electrical Engineering, MANIT
Bhopal, Madhya Pradesh, India (e-mail: mukeshkirar@rediffmail.com).
Ganga Agnihotri, professor, Electrical Engineering, MANIT Bhopal,
Madhya Pradesh, India (e-mail: ganga1949@gmail.com).
current of induction motor and the voltage flicker during start
up [6]. During motor starting, the voltage level at the motor
terminals should be maintained at approximately 80 percent of
rated voltage [7]. Factors affecting motor starting include
impedance of power distribution systems, the motor terminal
voltage, inertia of the motor and the load. System impedance
has impact on both starting current and motor terminal
voltage. Its impact on the voltage is much greater than on the
current. The starting current using across-line starting is only
slightly different when the impedance of the circuit is
changed, but the voltage drop on the cable changes
significantly [8].
II.SYSTEM DESCRIPTION
A single line diagram (SLD) of a power distribution system
of a large Oil Storage Terminal (OST) is shown in Fig. 1. To
improve system reliability and power quality, the ICP has Grid
connectivity with public power company (PPC) at two points.
PPC power is available at 66 kV voltage level through utility
ties 1 and 2. Grid transformers TR-301 and TR-302 step down
the voltage from the 66 kV level to the 6.9 kV level and
connected to Switchgear SG-201A and SG-201B through
cable respectively. The power is primarily distributed at a 6.6
kV level from two main receiving Switchgear panel SG-201A
and SG-201B. Emergency load is connected to MCC-401 and
MCC-402 and SG-402A and SG-402B panel. Generator rating
is calculated according to the load on the buses MCC-401 and
MCC-402 and SG-402A and SG-402B. When the plant
becomes isolated, due to a utility service outage generator will
supply power to emergency load. Emergency power is
generated at 6.6kV and supplied to load through generator
transformer TR-405 of 6.6/0.415kV.
III. STEPS FOR GENERATOR SIZING
Step –1: Segregation of Loads
It is important to gather a reasonably accurate load schedule
as soon as possible for determining generator rating as well as
overall system design. The detailed loads equipment
information is not available at early stage in project. The
primary sizing calculation have to be made based on estimates
and assumptions and the same must be iterated as more
accurate information becomes available progressively. After
accumulation of load list it is necessary to segregate the loads
in different application categories as listed below:
• Category-1: Linear loads like lighting, heating etc. in kW
(KWl
) and its overall pf (PFl
)
• Category-2: Running highest motor or a group of motors
Mukesh Kumar Kirar, Ganga Agnihotri
I
Emergency Generator Sizing and Motor Starting
Analysis
World Academy of Science, Engineering and Technology
International Journal of Electrical, Electronic Science and Engineering Vol:7 No:1, 2013
46
InternationalScienceIndex73,2013waset.org/publications/17299

•
•
•
to
C
de
ge
pr
ge
do
fo
to be starte
loads input
Category-
started inpu
Category-
overall pf (
Category-
(KWf
) and
Step-2: Effec
It is importan
o be just sum
onventionally
etermine a cos
enerator, effe
roperly to av
enerator to be
one in step-1
kW kW
Nu
= 1.25 *
or 6 pulse UPS
ed at a time o
t power in kW
3: Running m
ut power in kW
4: UPS inpu
(PFu
)
5: Soft started
its overall pf
ctive Load to G
nt to note that
of the loads
y that may be
st effective as
ective loads o
void generato
e calculated as
W kW kW
1.4 for 1 phas
S with input fi
or sum of aut
W (KWs
) and
motor loads e
W (KWm
) and
ut power in
d motor input
(PFf
)
Generator
generator rati
if some non-
taken care by
s well as proje
on generator
or over sizing
s below based
N kW
se and 6 pulse
ilters or 12 pu
to accelerated
its other para
Fig. 1 Sing
except VFD a
d its overall pf
kW (KWu
)
t power rating
ing is not nece
-linear loads p
y margin facto
ect required ra
must be cal
g. Effective l
d on load segr
N kW kW
UPS and 1.2
ulse UPS. Fact
d motor
ameters
gle line diagram
and soft
f (PFm
)
and its
g in kW
essarily
present.
or but to
ating of
lculated
load to
regation
(1)
5* 1.15
tor 1.25
is
sup
wi
kV
is
sti
rat
ne
ge
sta
wi
ge
to
like pf (PF
starting tim
m (SLD) of OST
considered to
pplying conne
Nf
= 1.15 for
ith bypass con
Effective KV
kVA
PF
Step-3: Overl
Overloading
VA rating not
low due to lo
ll continues t
ted motor sp
arly 0.7 to 0
nerator, volta
arting as per N
ith reduced v
nerator sizing
Considering s
be calculate
Fs
), starting cu
me (ts
) based on
T
o take the batt
ected loads.
without bypa
ntactor after st
VA rating of th
W
F
load Capacity
has to be che
the short tim
ow starting p
to 5-7 times o
peed even tho
0.8. In case o
age dip of 15
NEC. Even i
voltage startin
g keeping in vi
starting load,
ed as below
urrent (Is
), sta
n load type.
tery charging
ss contactor a
tart
he generator is
y
ecked with re
e kW rating.
ower factor w
of full load cu
ough power
of firewater
5% only to be
f firewater pu
ng, DOL to
iew criticality
short time to
without con
arting pf (PF
after drain ou
after start and
s
espect to shor
During startin
whereas line c
urrent up to 8
factor increa
pump connec
e considered
ump starter is
be consider
y of fire water
otal kVA load
nsidering corr
Fss
) and
ut with
1.0 for
(2)
rt time
ng, kW
current
80% of
ased to
cted to
during
s fitted
red for
pump.
d rating
rection
47

factors for non-linear loads.
kVA
W
PF

I K W
PF

W
PF

W
PF

W
PF
W
PF
(3)
where Kr
is to be selected from IEEE Std 399-1997
kVA kVA K (4)
However, if no data is available on overload capacity
K
= 1.5 could be considered and suitability to be
checked.
If above relationship is not fulfilled,
kVA corrected in Step 3
VA
K
(5)
Step-4: Step Loading Capacity
Step loading has to be checked with respect to short time
kW rating not with respect to the short time kVA rating. The
effect of step load is much more on engine/governor which is
responsible to deliver the desired kW. Step loading capacity is
fully depends on engine type and associated governor
type/response time. Usually governor type is unknown during
initial phase of project and conservatively maximum 40%
engine capacity could be considered as a permissible step
load. Again maximum starting load in kW shall be selected as
maximum step load. So the relationship given below is to be
checked considering 40% allowable step load. In case accurate
step load factor is obtained from vendor, the same is to be
applied instead of 0.4.
W I K PF
PF
kVA P. F. of Generator Step Loding Factor (6)
If it is not fulfilled,
kVA corrected in Step 4
W I K PF
PF P.F. F
(7)
Step-5: Transient Voltage Dip
The instantaneous transient voltage dip occurs during
starting of motor, is strictly a function of the relative
impedances of the generator and motor. Gen-set's ability to
start large motors without excessive voltage and frequency dip
is a function of the complete system.
Excitation systems that responds too quickly or too stiff can
actually overload the engine when starting large motors. In
general generator has to recover voltage at least up to 90% of
rated voltage utmost by few cycles. If the motor does not
reach near rated operating speed after few seconds (say 4 to 10
sec), a heavy voltage and frequency dip may occur. It is to be
noted that manual calculation of transient voltage drop does
not lead to any conclusive result. The exciter type, AVR
voltage change rate, and time constants of exciter are major
factors to determine whether generator is capable to recover to
90% voltage after transient dip. Keeping in mind this aspect,
transient voltage dip at motor starting could be calculated by
very simplified method ignoring other parameters of network
like cables and running loads.
%V
X"
X" KVA PF / W I K
(8)
V
X"
X" KVA PF / W I K
(9)
where V is allowable voltage dip
If above relationship is not fulfilled
kVA Corrected in step-5
5
KW I K
PF
X"
100
V
1
Step-6: Generator Rating
Generator electrical kW kW calculated
kW = Generator kVA kVA *0.8(Gene p.f.) (10)
Engine i.e. mechanical kW (kWm) selected
kWm = kWe selected / efficiency of engine (11)
Suitable design / future margin, normally 10 to 30%, should
be applied on above calculated kVAe rating and round off to
nearest rating available in market.
After exercising all of above five steps, Generator rating
shall be maximum rating out of calculation from step-2 to
step-5. According to different application categories, the load
is segregated in Table I. Flow chart for generator sizing is
given in Fig. 2. The generator rating selected after the
calculation is 5MVA. The generator parameters which are
considered in the study are depicted in Table V of appendix.
TABLE I
LOAD LIST
Type of the Load kW P.F. kW/Pf
Lighting/Heating Load (kWl
) 1000 0.9 1111
Highest Motor Load (DOL) (kWs
) 110 0.85 129.4
Running Motor Load (kWm
) 74.8 0.86 86
UPS Load (12 Pulse) (kWu
) 4 0.8 5
Soft Started Motor Load (kWf
) 55 0.85 64.7
Miscellaneous kW 2650 0.85 2887
Total 3893 4515
48

Fig. 2 Flow chart for generator sizing
IV. MOTOR STARTING ANALYSIS
To investigate the transient performance of Gene-set during
motor starting, the mathematical models of exciter, governor,
and load is considered in this study as given in appendix. The
transient and subtransient reactances of the generator and
motor are considered in the computer simulation so that more
accurate results can be obtained.
The gene-set’s ability to start large motors without large
voltage and frequency dips depends on the entire system.
System factors that affect generator operating characteristic
during motor starting include:
• Available engine power;
• Capacity of the generator;
• Energy stored in the rotating inertia of the gene-set;
• Impedance of power distribution systems;
• Electrical design parameters of the motor;
• Acceleration of the motor and its load (motor
characteristics);
• Motor terminal voltage.
A properly sized generator supports the high starting kVA
(kVA ) required and sustain adequate output voltage for the
motor so it can produce the required torque to accelerate its
load to rated speed. After the initial voltage dip, it is important
that the generator restore voltage to at least 90% to develop
adequate torque to accelerate its load to rated speed [9]. The
induction motor parameters considered in study are depicted
in Table IV of appendix.
A.DOL Starting of IM on Gene-Set: Case Study
Emergency loads are usually served by on-side generation
of limited capacity, which generally magnify voltage drop
problem on motor starting, especially when large motors are
involved. The DOL motor starting analysis is performed to
investigate generator performance, induction motor
performance and the performance of other connected load.
The motor starting study can expose and identify the extent of
a voltage drop problem [10]. The case study is performed with
the help of ETAP software.
The case study is executed for 0.415kV motor control
centre (MCC-402) in OST power distribution system. The fire
water pump motor rated at 110kW is connected to MCC-402
as shown in SLD Fig. 1. Motor starting analysis is done when
the entire load supplied by the gene-set is already in operation.
The summary of the load flow results are given in the Table II.
Design parameters of induction motor are given in
appendix. Motor starting current and the moment of inertia of
motor and load is taken according to motor data sheet. The
110kW motor (PM-026A) is connected to MCC-402 by 400m
long cable. The simulation results during DOL starting of
110kW induction motor, starting current, MCC-402 and motor
terminal voltage, slip, motor and load torque are shown in Figs
3-6 respectively.
Voltage difference between voltage at motor terminal and
the MCC-402 is due to voltage drop in the cable. Allowable
voltage drop in the cable during normal operation is 3% and
15% during starting time. The motor terminal voltage during
starting is 84.07% and then recovers slowly and stabilized at
the post starting value of 93.39%. The percentage is based on
nominal bus voltage.
Available Voltage at different buses as percentage of bus
nominal kV and time duration throughout DOL motor starting
is shown in Table III
TABLE II
LOAD FLOW RESULTS
Bus ID Nominal kV Operating kV (in %)
EPCC-401 0.415 96.87
MCC-401 0.415 96.5
MCC-402 0.415 95.81
PMCC-402A 0.415 95.73
MPCC-402B 0.415 95.68
SG-403 0.415 95.81
PM-026A 0.415 94.54
TABLE III
VOLTAGE DIP DURING MOTOR STARTING
Device ID Rated voltage % Voltage Operation Duration (sec)
PM-026B 0.415 84.2 11.18
EPCC-401 0.415 93.3 11.02
MCC-401 0.415 92.8 11.16
MCC-402 0.415 90.5 11.26
PMCC-402A 0.415 92.2 11.24
PMCC-402B 0.415 92.2 11.24
SG-403 0.415 92.3 11.22
49

F
Fig. 3
Fig. 4 Motor ter
F
Fig. 6 M
Motor starting
rminal and MC
v
Fig 5 Motor slip
Motor and Load
current variatio
CC-402 voltage
voltage
p during motor s
torques during
on with time
in % wrt bus no
starting
motor starting
ominal
ma
sta
sta
ex
po
siz
res
sta
sys
cap
wi
pro
typ
fre
fre
the
ge
go
flu
by
B.Generator
The power dr
ainly reactive
arting. Power
arting is shown
Fig. 7 Genera
During motor
citation curre
ower factor du
zing A.C. gen
sults in lower
Fig. 8 Genera
The dynamic
arting of indu
stem. It is c
pable of sup
ithout exceed
oducing a dan
pically depend
equency dip a
equency dip re
e percent of
nerator. Based
ood starting
uctuation. Acc
y motor starti
Power and PF
rawn by the i
e due to the l
r output of t
n Fig. 7.
ator output pow
r starting, low
ents and resul
uring motor s
nerators for o
operating effi
ator power facto
V.CON
behavior of g
uction motor
oncluded from
plying both
ding its desig
ngerously dep
ds on the perm
and the accept
ecovery time.
load step and
d on the given
performance
cordingly, it is
ing analysis t
F during DOL
induction mot
low power fa
the generator
wer variation dur
wer power fac
lts in increase
starting is sho
operation at l
iciency and hi
or variation dur
NCLUSION
gene-set unit d
s is interestin
m above resu
steady state
ned frame ov
pressed voltag
missible percen
table duration
Generator rat
d type of loa
n results it is c
in terms
s concluded fr
that the moto
L IM starting
tor during star
actor at the t
r during the
ring motor start
ctor demands
ed losses. Gen
own in Fig. 8
ower power
igher costs.
ring motor start
during direct-o
ng in grid is
ults the gene
and transient
verload capac
ge. Generator
ntage of volta
n of the volta
ting also depe
ad connected
clear generato
of lowest v
rom results ob
or can DOL
rting is
ime of
motor
ting
higher
nerator
8. Over
factors
ting
on-line
solated
e-set is
t loads
city or
sizing
age and
age and
ends on
to the
or gives
voltage
btained
started
50

satisfactorily. This paper can be used as a design guide for
generator selection. Motor starting study on gene-set must be
performed at the design stage. If the system shows motor
starting difficulty due to excessive voltage drop in the system,
a new system configuration should be chosen to avoid the
problem. Considering both the cost and performance of a
standalone gene-set system should be carefully evaluated to
select appropriate size during the design stage.
APPENDIX
A.IEEE Type 1 - Continuously Acting Regulator and Exciter
Fig. 9 Exciter block diagram
TABLE IV
INDUCTION MOTOR DATA
kW kV Full Load
Current
P.F. LRC in % of
full load current
Starting P.F. LRT in % of full load
torque
Max. Torque in %
of full load torque
X/R H
110 0.415 179 0.88 600 0.25 98.69 199 11.1 0.92
TABLE V
GENERATOR DATA
kVA kV P.F. H " " " "
5000 6.6 0.85 2.4 0.11 0.12 0.23 1.1 0.12 0.15 1.08 0.002 5.6 0.002
REFERENCE
[1] IEEE Recommended Practice for Industrial and Commercial Power
Systems Analysis, IEEE Std 399-1997 , vol., no., pp.I, 1998
[2] IEC 60034-12:1980, “Rotating electrical machines” Part 12: Starting
performance of single speed three-phase cage induction motors for
voltages up to and including 660 V
[3] Rotating electrical machines – Part 1: Rating and performance, IEC
60034-1, 1999-08.
[4] IEEE Recommended Practice for Protection and Coordination of
Industrial and Commercial Power Systems," ANSI/IEEE Std 242-1986 ,
vol., no., pp.0_1, 1986.
[5] A. Jack Williams, M. Shan Griffith, "Evaluating the Effects of Motor
Starting on Industrial and Commercial Power Systems," Industry
Applications, IEEE Transactions on, vol.IA-14, no.4, pp.292-305, July
1978.
[6] P.S. Patil, K.B. Porate, "Starting Analysis of Induction Motor: A
Computer Simulation by ETAP Power Station," Emerging Trends in
Engineering and Technology (ICETET), 2009 2nd International
Conference on , vol., no., pp.494-499, 16-18 Dec. 2009
[7] IEEE Recommended Practice for Electric Power Distribution for
Industrial Plants” IEEE Std 141-1993.
[8] Liang Xiaodong, O. Ilochonwu, "Induction Motor Starting in Practical
Industrial Applications," Industry Applications, IEEE Transactions on ,
vol.47, no.1, pp.271-280, Jan.-Feb. 2011
[9] John H. Stout “Capacitor Starting Of Large Motors ” IEEE Transactions
On Industry Applications, Vol. Ia-14, No. 3, May/June 1978, pp. 209-
212
[10] A. Jack Williams, JR. Member, M. Shan Griffith, “Evaluating the
Effects of Motor Starting on Industrial and Commercial Power Systems”
IEEE Transactions On Industry Applications, Vol. IA-14, NO. 4,
JULY/AUGUST 1978
Mukesh Kumar Kirar was born in Narsinghpur, India, in 06 Feb 1983. He
received the B.E. (Electrical) degree from Government Engg. College, Ujjain,
India in 2006 and M.Tech. (Power System) in 2008 and pursuing Ph.D from
MANIT Bhopal, India. He is currently working as an assistant professor in the
Department of Electrical Engineering, MANIT, Bhopal, India. His field of
interests are power system stability and control, transformers and machines.
Ganga Agnihotri was born in Sagar, India, in 27 May 1949. She received the
B.E. (Electrical) degree from MACT, Bhopal, India. She received the M.E.
(Advance Electrical Machine) and PhD (Power System Planning Operation
and Control) from University Of Roorkee, Roorkee in 1974 and 1989
respectively. She is currently working as a professor in the Department of
Electrical Engineering, MANIT, Bhopal, India. She has 12 research papers in
International journals, 20 research papers in National journals, 22 research
papers in International Conferences and 70 research papers in National
Conferences. Her fields of interest are Power System Planning, Power
Transmission Pricing, Power System Analysis and Deregulation. Dr.
Agnihotri has a membership of Fellow IE (I) and LISTE.
51

Emergency generator sizing and motor starting analysis

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