Sizing Generators for Motor Starting
Presented By: Valley Power Systems, Inc.
Nomenclature Review
Why Size Matters
Selecting the Right Generator
Considerations for Electric Motor Loads
Introduction to Variable Frequency Drives (VFDs)
AGENDA How VFDs Reduce Energy Consumption
The Impact of VFDs on Generator Size
Conclusion
Q&A
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Nomenclature Review
4
Nomenclature Review
RATING – Standby vs. Prime Power
RPM – Engine Speed
HZ – Frequency
VOLTS – Output of Generator
PHASE (Φ) – Single or Three
AMPS - Current
AMPS/TERM – Amps per
Terminal
FIELD VOLTS – Excitation volts
required for RMF
FIELD AMPS – Current required
for RMF
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Nomenclature Review – Continued…
KW – Actual Power to Perform
Mechanical Work
KVA – Apparent Power
Power Factor (PF) – Ratio of
Actual Power (kW) to Apparent
Power (kVA)
INS CLASS – Temperature the
insulation materials are rated
TEMP RISE – Winding
Temperature over ambient
AMB – Ambient Temperature
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Nomenclature Review
Power Factor Explained
Power factor measures how effectively electrical
power is used in a circuit
Power factor is the ratio of real power (kW) used by
a circuit to the apparent power (kVA) delivered to
the circuit
PF = kW / kVA
Power factor can be better understood as a loss that
results from the conversion of electrical energy to
mechanical work output
Inductive loads cause the current to lag the voltage
resulting in a lagging power factor
Loads with a low power factor require a large
amount of apparent power relative to the amount of
actual power doing the work
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Nomenclature Review
Apparent • Total power delivered to the
Power load by the source “The Beer Analogy”
• Foam + Drinkable Beer
(kVA)
Active • Real power consumed by the
Power load to do the work
• Drinkable Beer
(kW)
Reactive • Power consumed that does
not result in mechanical
Power work
(kVAR) • Beer Foam
Power • The ratio of active power to
Factor apparent power
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Nomenclature Review – Continued…
Frequency Dip: The
Voltage Dip: The effect
effect that applying a
that applying a load has
load has on the frequency
on the voltage output of
output (engine speed) of
a generator
a generator
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Nomenclature Review
– Continued…
Examples of Common Single-Phase Loads
Lighting
Many Power Tools
Heaters
Some Electric Motors
Some Pumps, Fans, and Compressors
Some HVAC Systems
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Nomenclature
Review –
Continued…
Examples of Common Three-
Phase Loads
Electric Motors
Many Pumps, Fans,
and Compressors
Conveyor Systems
Heavy Machinery
Telecommunications
Equipment
Large Industrial
HVAC Systems
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Why Generator Size Matters
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Why Size Matters
Optimized Reliability Compliance with Cost-Effective
Performance Regulations Operation
13
Why Size Matters
Special Considerations for Tier 4 Final
Critical to Impact on
Preventing Wet
Emissions Aftertreatment Fuel Efficiency
Stacking
Control Systems
14
In the Age of Tier 4 Final – Load is King!
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Selecting the Right Generator
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Selecting the Right Generator
Many Resources and Sizing Calculators Online
https://apps.apple.com/us/app/light-the-power/id1455355698
Form a list of all items that will be powered and
calculate the total power demand to start and run
the system
Perform criticality ranking to determine how
much of the facility must stay online in the event
of an emergency
Safety – Will an outage create an immediate
danger
Environmental – Will loss of power create a
problem
Collateral Damage Potential
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Selecting the Right Generator – Continued…
Determine how much power is
required to start the system
Determine how much power is
required to run the system at full
load
These figures are typically
inscribed on the equipment
nameplate and recorded in the
OIM manual
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Selecting the Right Generator – Continued…
Survey the site to
determine how many
circuits to power
Large capacitive loads
such as UPS systems and
computer banks should
be discussed with the
equipment provider
If using portable / non-
permanent generators, a
manual transfer switch
“tap box” can provide
Example of an external “tap box” Manual Transfer Switch
easy access/installation
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Selecting the Right Generator – Inductive Loads
Large inductive loads, like electric motors, pumps, and compressors,
draw significantly higher current (up to 8x running current) when
starting
The generator must be sized to handle these large initial inrush
currents to prevent voltage dips or system overloads during start-up
Inductive loads typically have a lower power factor
A generator must provide sufficient kVA capacity to support both real
power (kW) and reactive power (kVAR)
Generators supporting inductive loads often experience voltage dips
when these loads start or change
Ensuring proper sizing helps minimize recovery time and maintains
stable voltage and frequency levels
Some inductive loads, particularly those controlled by variable
frequency drives (VFDs), can introduce harmonic distortion
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Considerations for Electric
Motor Loads
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Considerations for
Electric Motor Loads
A rule of thumb is to size the generator
for 300% of the motor rating, but this may
not always work out as planned
The inrush current, resulting voltage dips,
and the relative impact on other loads
from starting electric motors must be
considered when sizing a generator
Special electric motor starting devices can
greatly reduce the size of the generator
required by controlling the inrush current
during start-up
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Techniques to Mitigate Voltage & Frequency
Dips During Motor Starting
Size generator for peak power demand to handle the
voltage dips and frequency dips resulting from the
inrush current during motor start-up
Develop a starting sequence strategy for electric
motors to throttle the demand
Autotransformer starters and wye-delta starters offer
controlled voltage reductions during motor start-up
Reduced-voltage starters and soft-start systems lower
initial current and torque demand
Variable frequency drives (VFDs) provide precise
control over the inrush current during start-up
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Electric Motor Starting Methods
Direct-On-Line (DOL)
Simple Start-Up Method:
Motor is connected directly to the
power supply
High Inrush Current:
DOL starting typically causes an
inrush current up to 6-8 times the
motor’s full load current, which
can stress electrical components
and cause voltage dips.
Suitable for small motors or
applications where high inrush
current is acceptable
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Electric Motor Starting
Methods
Star-Delta Starting
Starts in the Wye (star)
configuration, reducing voltage and
current, then switches to Delta
configuration for normal operation
Limits inrush current to
approximately 30-33% of the DOL
value, reducing electrical stress and
improving system stability
Reduces inrush current but has
torque limitations
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Gradual Voltage Increase: Soft
starters gradually increase voltage to
Electric the motor over a set time
Inrush Current Control: Unlike DOL
Motor starting, soft starters limit inrush
Starting current to just 2-3 times the motor’s
full load current
Methods
Cost-Effective Solution: A soft starter
is a cost-effective alternative for
Soft Starters applications that require reduced
inrush current but do not need full-
speed control
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Electric Motor Starting Methods
Variable Frequency Drives (VFDs)
Significant Inrush Reduction:
VFDs adjust the frequency and voltage supplied
to the motor, limiting the inrush current
Full Speed Control:
VFDs allow precise control of motor speed and
torque by adjusting the frequency and voltage
supplied to the motor
Energy Savings:
Significant energy savings in applications that
don’t require the motor to run at full speed
constantly
Enhanced Features:
VFDs offer greater functionality, such as torque
control, feedback systems, and integration with
automation systems
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What is a Drive?
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Electric motors are everywhere!
But when they’re directly connected
This is pretty inefficient.
to the electrical supply, the motor’s
speed is fixed, whether the task
requires that level of constant power
or not.
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Electric motors consume over 70% of the
world’s electricity. Reducing our energy
consumption translates to a reduced
energy bill
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VFDs enable motors to use electricity efficiently.
By positioning a drive between the electrical supply
and the motor, power is fed into the drive, and the
drive then controls and regulates the power that is fed
into the motor.
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This allows control of
speed, direction,
acceleration, deceleration,
torque and, in some
applications, position of the
motor shaft.
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The drive does
this by changing
a constant
frequency,
constant voltage
supply…
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… into a
variable
frequency,
variable
voltage
supply.
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By continually calculating
and adjusting the frequency
and voltage, the motor
receives only the power
needed for the task at hand.
This means lower and a smaller
energy costs, lower carbon footprint.
maintenance
costs,
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VFD System Benefits
ENERGY SAVINGS REDUCES PEAK REDUCES POWER REDUCES VOLTAGE
ENERGY DEMAND WHEN NOT SPIKES ON START-UP
REQUIRED
FULLY ADJUSTABLE CONTROLLED SELF-DIAGNOSTICS ADVANCED
SPEED STARTING, AND OVERLOAD
STOPPING, & COMMUNICATIONS PROTECTION
ACCELERATION
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Summary
Most motors are designed to rotate at a set
speed. They cannot alter their speed.
VFD: Variable Frequency Drive
VFDs provide effective speed control of
electric motors by modulating the voltage
and frequency.
By controlling the speed of the motor users
can achieve improved process control,
reduced wear on machines, increased power
factor, and substantial energy savings.
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How VFDs Reduce Energy
Consumption
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Affinity Laws & Square Law
Fluxing
How PID Control
VFDs Save
Active Front End Systems (AFE)
Energy
Common DC Bus Systems
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How VFDs Reduce Energy Costs & Consumption
Affinity Laws for Variable-Torque Loads
The most significant energy savings can be achieved in
applications with variable torque loads.
The Affinity Laws for variable-torque loads describe the impact
of changes in speed on pumps and fans.
Altering the speed of variable torque loads can yield power
savings proportional to the speed reduction cubed.
The easiest way to achieve large cost and energy savings for most
motion control applications is to reduce the speed of the motor!
𝑄𝑛𝑒𝑤 𝑁𝑛𝑒𝑤
Law #1: =
𝑄𝑜𝑙𝑑 𝑁𝑜𝑙𝑑
𝑃𝑛𝑒𝑤 𝑁𝑛𝑒𝑤 2
Law #2: = 𝑓𝑡 3
𝑃𝑜𝑙𝑑 𝑁𝑜𝑙𝑑 Q= Flow Rate (𝑚𝑖𝑛) N = Pump Speed 𝑅𝑃𝑀
𝐻𝑃𝑛𝑒𝑤 𝑁𝑛𝑒𝑤 3
Law #3: = P = Pressure (𝑚𝑒𝑡𝑒𝑟𝑠 ℎ𝑒𝑎𝑑) HP = Power Drawn (𝐻𝑃)
𝐻𝑃𝑜𝑙𝑑 𝑁𝑜𝑙𝑑
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How VFDs Reduce Energy Costs & Consumption
PID control is a feedback mechanism in control systems that
combines three distinct strategies: Proportional, Integral, and
Derivative control.
A closed-loop system that dynamically varies the speed of the
motor to precisely match the load demand for the application.
A feedback device (i.e., Sensor) is required.
Most Common PID Control Loop is a Home Thermostat
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How VFDs Reduce Energy Costs & Consumption
Active Front End Systems Common DC Bus Systems Combining AFE w/ Common DC Bus
(AFE)
Use a controlled rectifier Circulates energy between Provides for maximum
bridge. braking and motoring drives to flexibility!
reduce running costs.
Enable bi-directional energy Allows energy flow between
flow between the mechanical Effective in applications like drives and bi-directionally with
system and AC supply. unwinding and rewinding the line supply.
materials and maintaining
material tension.
Provide higher efficiency, Often involves a single AFE
especially in applications with unit with multiple DC bus
electrical braking. Energy is required mainly to connected drives.
supply system losses.
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The Impact of VFDs on
Generator Size
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How VFDs Enable the Downsizing of a
Generator
Reduced Starting Inrush Current:
VFDs eliminate the large inrush current
associated with the motor startup by
gradually ramping up both the voltage and
frequency.
This reduces the peak power demand on the
generator, allowing the use of a smaller
generator.
Variable Speed Control:
VFDs adjust motor speed to match the load
requirements rather than running the motor
at full speed constantly.
This means the generator can operate at
lower power levels for much of the time,
further reducing overall power demand.
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How VFDs Enable the Downsizing of a
Generator
Improved Power Factor:
VFDs improve the power factor of the motor
system, reducing the reactive power demand
on the generator
Energy Efficiency:
VFDs ensure that the motor only consumes
the necessary energy for the given load,
reducing the overall power requirement
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Impact of VFDs on Generator Size
Example: Sizing a Standby Generator for (3) 100 HP, 460 V Pumps
Across the Line (No VFD) With VFDs
600 kW Generator 250 kW Generator
Running Load Factor = 39% Running Load Factor = 97%
Voltage Dip = 23.69% Voltage Dip = 11.84%
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Harmonics and VFDs
Variable Frequency Drives (VFDs) can introduce
electrical harmonics into a system, which are
distortions in the voltage and current waveforms
Result: inefficiencies, overheating in motors / generators,
and potential damage to equipment.
To reduce harmonics, solutions such as line reactors,
harmonic filters, active front-end (AFE), or 18-pulse
VFD configurations can be used.
See manufacturer’s recommendation for allowable 47
temp. rise while running power drive systems.
Conclusion
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Key Takeaways
Proper Generator Sizing is Critical
Electric Motor Loads Need Special Attention
VFDs Help Reduce Generator Size
Energy Efficiency and Cost Savings
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Practical Steps for Sizing Generators for
Electric Motor Loads
Determine
• Determine Starting and Running Power Requirements
Consider
• Consider Inrush Currents
Account
• Account for Voltage and Frequency Dips
Use
• Use VFDs or Soft-Starters
Develop
• Develop a Load Sequence Strategy
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THANK YOU!
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