SpecSizer and Generator Set Sizing

This document is intended to help a new user utilize the Electric Power SpecSizer program effectively,
and will focus on the terms used and questions asked while sizing a generator set for a customer’s
application. It is not an exhaustive guide to engineering principles or application analysis; for details on
these issues, we refer you to Caterpillar’s Application and Installation Guide, subtitled ‘Electric Power
Applications, Engine & Generator Sizing”, LEBE5294. However, a familiarity with basic terms and
principles is essential before the program can be used effectively, and this forward is intended to give an
overview of these issues.

A generator set (often referred to as genset) at its minimum consists of an engine and a generator,
which work together as a system. Each has unique characteristics, but together these qualities
determine the performance and sizing of the genset system.

Engines produce brake horsepower (or kilowatts – real power) while controlling speed or frequency via
their governor. Generators are primarily responsible for converting the engine power into kilovolt-
amperes (kVA) and electrical kilowatts (kW) while controlling voltage via the voltage regulator. They
also must satisfy high “magnetizing current” (kVAR) for inductive type loads such as motors and
transformers. Together, the kW, kVA, and kVAR represent the three legs of a right triangle, and the
cosine of the angle between kVA and kW defines the power factor of the system. Each of these terms
comes up frequently.

Engines are sized according to the actual power in kW required to meet the needs of the facility, and the
generator is sized to match or exceed the engine power capability.

The power required by the installation can be calculated by adding the nameplate ratings of the
equipment on site, while considering efficiencies and the power factors of the driven equipment.

There are many kinds of common loads to consider (motors, lights, computers, etc) and they often have
substantially different impacts on genset sizing. However, they all are measured by the same
parameters, and the following is intended to give a high level perspective of the load parameters
important to sizing.

RUNNING PARAMETERS: Running kW (RkW): This is the steady running electrical power required to
drive all of the loads that are connected to the genset at the same time. This power, when divided by
the generator efficiency, is the amount of Brake kW (BkW) required from the engine to drive the
generator.

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 Running kVA (RkVA): This is another measure of the steady running electrical power required from the
generator. All of the loads are usually at the same voltage, and each requires a certain amount of
current in amps. The product of the volts and amps, divided by 1000, is the RkVA required by the site,
and is the primary measure of the size of the generator.

Running Power Factor (RPF): Because loads usually have some inductance or capacitance, the current
sine wave is usually not in exact phase with the voltage sine wave. As stated above, the cosine of the
resulting phase angle difference is the power factor of the load. This is important, because the
relationship between real power (RkW) and RkVA is the power factor:

kW = kVA * RPF

Running Non-Linear Loads: More and more, sites contain many loads that are classed as non-linear.
These are typically devices containing solid-state circuitry that switches on and off at high frequency,
such as AC/DC converters. The simplest example is a battery charger. This switching causes harmonic
wave forms to be superimposed on the primary sine wave, resulting in a distorted voltage waveform
that can disturb both the loads in the system, and the control system of the generator. In addition,
these switch pulses can cause the voltage and current to be out of synch, so that they don’t vary
proportionally, thus the term non-linear loads. This results in increased generator heating and reduces
generator insulation life.

SpecSizer increases the specified alternator size by defined amounts to mitigate the harmful effects of
waveform distortion and insulation heating caused by Non-Linear loads.

Unbalanced Loads: The effects of a single-phase load must be accounted for. Its kW demand is treated
no differently than a 3-phase load. However, the kVA load is applied to only a single generator phase,
which causes heating in that phase. Thus, the entire generator must be sized to accommodate the “hot”
phase. SpecSizer allows a user to distribute a single-phase load on any or all L-L and L-N phases. Lighting
loads are sized as a Distributed 3-Phase load.

STARTING PARAMETERS: Each of the above parameters (RkW, RkVA, RPF, and Running Non-Linear loads
describe the requirements of the load system at steady state running conditions. In addition, however,
each of these parameters has a value that may differ significantly while the load is being started, or
energized. Thus, there are analogous terms, such as SkW, SkVA, SPF, and starting non-linear load that
must be considered for genset sizing as well.

Starting loads are typically so brief that they’re unlikely to do harm such as overheating. They can,
however, have serious effects on transient genset performance, and therefore are often responsible for
sizing the genset. The oversizing effects of starting loads with high inrush can be mitigated by starting

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 loads in multiple load steps, or the use of reduced voltage starters or current limiting for motors. In
addition, starting loads with low(er), more restrictive transient dip requirements in later load steps can
often reduce the genset size requirement. If a load can be considered light-loaded (minimal inertia to
move), the Starting kW requirement can be reduced as well.

Starting kW (SkW) & Frequency dip: The kW when starting is often different than that required while
the load is steady running. Motors are typically the worst offenders, often requiring 2-3 times as much
engine power when starting as when they are running. Since motor starts can persist for many seconds,
this extra power demand must be included in the genset size, to prevent excessive frequency dip, or
even genset stall.

Starting kVA (SkVA) & Voltage dip: The kVA when starting also often differs from the running value, and
again the worst offender is usually motor. Because motors have such low resistance at low speed, their
kVA demand can be on the order of six times as much as when running steady state. Although this high
kVA is usually too brief to cause harm from overheating, the high inrush kVA occurs instantly. The
generator and its control system have unavoidable lags, resulting in a significant voltage dip before the
generator controls can catch up and return voltage to normal values. If excessive, this voltage dip can
cause lights to dim and other loads to malfunction. At the very least, there may be a site specification
that limits voltage dip to an acceptable value. Finally, some loads at your site may have stringent
voltage dip requirements. Fire pumps for example, are limited by local codes to no more than 15%
voltage dip. (Reference Permitted Voltage Dip % on all SpecSizer load dialogues). Be aware that all loads
and load steps sequenced after a load with a more restrictive (i.e. 15%) frequency dip or voltage dip will
adopt that more restrictive dip. For example, motors, other loads, etc. requiring only 30% dip, 20% dip,
etc. will need to and be sized at 15% dip. This will almost always upsize the genset selection. Start and
sequence loads with restrictive voltage and frequency dip in later load steps, if possible.

Starting Non-Linear Loads: Except in extreme cases, the effects of non-linear loads are not enough
different during starting to warrant special treatment in genset sizing. However, Non-Linear loads do
increase the Running kVA (RkVA) demand of the alternator. SpecSizer will indicate this increased kVA
demand with the Total kVA (TkVA) value increased from the RkVA value in the SpecSizer “LOAD
ANALYSIS SUMMARY”. The difference is the additional load kVA resulting from the Non-Linear load(s).

INPUT vs. OUTPUT: No load is perfectly efficient and the efficiency loss is the difference between loads
described as having a size termed as “input” versus “output”. Resistive devices, for example, have a size
based on the input to the device, such as a space heater or incandescent light. Motors, on the other
hand, are often sized by the HP they provide to their driven load, thus their size is expressed in output
terms. The load demanded from the genset for such loads is their output divided by their efficiency.
(Reference Load Type on SpecSizer Load Dialogues)

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 SIZING OVERVIEW (first principals) The selected genset absolutely MUST be big enough to provide the
total values of RkW and RkVA, plus any additional generator capacity needed for Non-Linear loads or
unbalanced loads. This represents the absolute minimum genset size that can be specified, assuming
that the site load analysis is complete. On the other hand, loads with high SkW or SkVA can require a
larger genset, to avoid excessive frequency or voltage dips when the loads are starting.

Again, whenever possible, loads with high starting demands or with voltage dip or frequency dip
restrictions should be started in multiple steps (e.g., start the big motor first, then the voltage dip
sensitive load later). If the site conditions allow, the genset size can ideally be minimized to that
required by running loads. SpecSizer includes an Optimizer that will help distribute loads logically in up
to forty load steps, in order to minimize the size of the required genset. The Optimizer runs
automatically in the background upon advancing to SpecSizer’s “Select Genset” page from the “Add
Loads” page. If an optimized load scenario exists, that option is noted in an upper yellow bar on the
“Select Genset” page. From the “Select Genset” page, you may “Go to Optimized Scenario”, which will
resequence your loads and load steps, as well as determine your optimal number of load steps on the
“Add Loads” page, and then allow you to “Continue” and return to the “Select Genset” page. A smaller
EkW/kVA genset (possibly even Model) will be recommended, as well as typically a less number of load
steps along with the resequencing of loads in the load steps. Yet, you may undo the optimization by
selecting “Return to Original Scenario” on the “Select Genset” page… before saving the file… or save and
accept the optimized scenario. If you do, SpecSizer will append the text “-Optimized” after your original
filename, as well as save (and not delete) your original file as its own file name.

Sizing Steps: Sizing a genset typically involves four major steps, most of which SpecSizer automates for
you:

Step 1: Define each of the individual loads; enter their size, (input or output). SpecSizer will provide
appropriate default efficiencies, power factors, etc., but you may change most of them if your
information (spec) requires you to. Define other parameters required by the load dialogue, such as
number of phases, units of size (kW, kVA, amps), or allowable voltage dip and frequency dip. The end
results are the genset requirements for each load.

Step 2: Collect these loads into logical load steps. Distribution may be dictated by life & safety urgency
(life support equipment first), or sizing issues (big loads first). In some cases, a specification may require
that all loads start in a single load step. The output from this distribution process is the genset
requirement for each load step.

Note: if your site has motors that start and stop intermittently (elevators, air conditioners), SpecSizer
collects them into an additional “intermittent” step that is assumed to start last. This can sometimes
determine the size of your genset, because motors can cause high voltage dips, and you may have
already started loads that are sensitive to voltage and frequency dip. You set the Intermittent Step
percentage on SpecSizer’s “Define Site Conditions” page, and 25% is the default. A larger percentage of
motors starting intermittently typically sizes a larger genset. See the Help topic in SpecSizer for more on
Intermittent Motors and the Intermittent Step.

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 Step 3: Identify the peak requirements resulting from the combination of these load steps. For example,
a large motor started in load step #3 might require a higher peak starting kW requirement from the
engine than when energizing lights in the subsequent load step #4.

Step 4: Considering each of the sizing factors (RkW, RkVA with non-linear & unbalanced load allowances,
SkW, SkVA, allowable voltage dip and frequency dip in each step, etc.) select a genset that meets all of
them. A comparison of the requirements at the bottom of the selection screen, in the LOAD ANALYSIS
SUMMARY, to the parameters of the proposed genset is recommended, because it may cause you to re-
think your final choice. For example, if the selected set is just barely large (EkW/kVA) enough and the
site is likely to grow, you might wish to upsize a step. Note: you can do this manually from the “Select
Genset” page, or add additional “Expansion Capacity (%)” to the final genset selection using that feature
located on the “Define Site Conditions” page.

The same might be true if you have a significant (large) load that may have uncertainty in its size or duty.
Alternatively, if you’ve been very generous in your load estimates and your selection just barely creeps
into an EkW/kVA step size, you might possibly select a smaller genset by reexamining some of your most
conservative assumptions.

Similarly, if you suspect a large non-linear load may be responsible for oversizing, testing that load with
a harmonic filter can occasionally result in a smaller genset recommendation. Or you may be able to
utilize a higher pulse rectifier, say 24 pulse vs. 6 pulse. The smaller genset might more than offset the
additional filter cost. This situation can also arise with large motors. If a motor starter is acceptable in
the application, it might be less costly than a larger genset. VFD/VSD, Soft Starter, Wye Delta, etc. versus
Across the line (or Direct On line) starting greatly reduce the inrush (SkW & SkVA) demand of a large
motor, although VFD/VSD and Soft Starter contribute some additional harmonics. For example, Wye
Delta reduces the starting demand of the motor by 67%.

While SpecSizer does an outstanding job of easily collecting your information and accurately
recommending a Best-Fit genset for the site and load specifications you provide, it is prudent to re-
examine your load and site assumptions as you finish, especially if you see you’re at an EkW/kVA or
model borderline for the recommended genset.

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