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Generator Sizing The Ultimate Guide

This document provides a guide to sizing industrial generators. It outlines a 6-step process: 1) determine the generator purpose, 2) identify power requirements, 3) understand motor starting methods, 4) consider environmental factors, 5) choose a fuel system, and 6) calculate the generator size. The guide stresses including safety margins and consulting generator experts. It explains standby generators provide backup during outages while prime generators act as the primary power source. Motor starting methods, load types, and environmental conditions impact required size.

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Rashedul Islam
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
212 views

Generator Sizing The Ultimate Guide

This document provides a guide to sizing industrial generators. It outlines a 6-step process: 1) determine the generator purpose, 2) identify power requirements, 3) understand motor starting methods, 4) consider environmental factors, 5) choose a fuel system, and 6) calculate the generator size. The guide stresses including safety margins and consulting generator experts. It explains standby generators provide backup during outages while prime generators act as the primary power source. Motor starting methods, load types, and environmental conditions impact required size.

Uploaded by

Rashedul Islam
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Sizing an Industrial Generator – The Ultimate Guide

Generator Sizing
Industrial generator sizing can be a daunting task, especially if you are new to the world of backup power solutions. In
this paper, we will break down the complexities of generator sizing and guide you through the recommended procedures
for both standby and prime applications. We will also discuss important factors such as environmental considerations,
fuel systems, types of loads, and the impact of motor starting methods on generator size.

Step 1: Determine the Generator


Purpose
Before diving into the nitty-gritty of generator sizing,
it is essential to determine the purpose of the
generator. Generators are generally classified into
two categories: standby and prime applications.

Standby generators provide backup power during


utility outages, ensuring business continuity and
minimizing downtime. These generators are
designed to work for short periods. By definition,
standby generators can run for the duration of a
power outage: whether it is 5 min, 5 hours, or 5 days.
Prime generators, on the other hand, are used as the
primary power source in locations where utility power is unavailable or unreliable. They are built to operate continuously
or for extended periods, making them ideal for remote sites or off-grid applications.

Step 2: Identify Power Requirements


Once you've determined the purpose of the generator, it's time to assess your power requirements. Make a list of all the
equipment requiring power, including lighting, HVAC, computers, and machinery, etc. It's essential to consider the types
of loads your generator will be handling:

Resistive loads: These are loads that don't change their power factor, such as lighting and electric heating.

Reactive loads: These loads have inductive or capacitive components, such as transformers, motors, and capacitors.
Reactive loads can cause voltage fluctuations, making generator sizing more complex.

Non-linear loads: These loads generate harmonic currents that can distort the generator's output waveform, causing
overheating and reduced efficiency. Examples of non-linear loads include variable frequency drives (VFDs),
uninterruptible power supplies (UPS), and computer equipment.

Copyright 2023 Kinsley Power Systems


www.kinsley-group.com
Sizing an Industrial Generator – The Ultimate Guide

Step 3: Understand Motor StarƟng Methods


Motor star ng methods can signiÞcantly impact the size of your generator. There are three common star ng methods:
Across-the-line (ATL) star ng: This method applies full voltage to the motor, resul ng in high star ng currents. DOL
star ng requires a larger generator to handle the inrush current.
Star-delta star ng: This method reduces the star ng current by connec ng the motor windings in a star conÞgura on
during startup, then switching to a delta conÞgura on for normal opera on. Star-delta star ng requires a smaller
generator than DOL but may not be suitable for all motor types.
So starters and variable frequency drives (VFDs): These electronic devices control the motor's voltage and frequency,
allowing for a gradual increase in speed and minimizing inrush
currents. They require a smaller generator but can produce
harmonics that may necessitate addi onal sizing considera ons.

Step 4: Consider Environmental Factors


Environmental factors play a crucial role in generator sizing. High
al tudes, extreme temperatures, and high humidity can affect
the generator's performance, necessita ng a larger unit. Consult
the generator manufacturer's guidelines for dera ng factors to
account for these environmental condi ons.

Step 5: Choose a Fuel System

The choice of fuel system can impact the size and overall
efficiency of your generator. Common fuel op ons include diesel,
natural gas, and propane. Each fuel type has its advantages and disadvantages in terms of cost, availability, and
environmental impact. Consider your speciÞc needs, loca on, and budget when selec ng a fuel system for your
generator.

Step 6: Calculate Your Generator Size

Now that you've gathered all the necessary informa on, it's me to calculate the size of the generator you need. Start by
adding up the total power requirements of all the equipment you need to power. Remember to account for the types of
loads, motor star ng methods, and environmental factors.

For standby generators, it is essen al to include a safety margin in your calcula ons. This ensures that your generator can
handle unexpected load increases or future expansion. A general rule of thumb is to add 20-30% to your total power
requirements.

For prime generators, consider the generator's con nuous power ra ng, which is the maximum power it can produce for

Copyright 2023 Kinsley Power Systems


www.kinsley-group.com
Sizing an Industrial Generator – The Ultimate Guide

an extended period. Ensure that your generator can handle the peak load requirements while maintaining a safety
margin.

Finally, consult with a generator manufacturer or specialist to verify your calcula ons and help you choose the right
generator for your needs.

Conclusion
Sizing an industrial generator does not have to be complicated. By following the recommended procedure for generator
sizing in standby and prime applica ons, considering environmental factors, fuel systems, types of loads, and the impact
of motor star ng methods, you will be well on your way to selec ng the perfect generator for your speciÞc needs.

Keep in mind that this guide is meant to simplify the process and provide a general understanding of industrial generator
sizing. For a more accurate and detailed assessment, always consult with a generator specialist or manufacturer before
making a Þnal decision.

Please call your Kinsley Power Systems representative at 800-255-3503 to schedule


a sizing consultation or CEU-eligible class.

For additional help, download the Kohler Generator Sizing tool.

WWW.KINSLEY-GROUP.COM

Copyright 2023 Kinsley Power Systems


www.kinsley-group.com

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