The attached loads list has been done as required by the management to be considered when

determining generator size capacity required to cover Dhahab existing loads and additional loads
intended to be added as discussed with all concerned parties in the field.

Accordingly, the list been done based on the followings:

 All loads KW power and current recorded in the list are done according to the equipment
nameplate ratings provided by manufactures.
 In September and October, we struggled with operation in keeping the load absorbed as low
as possible to be handled by the 160KW Generator so the followings have been done:
 Switching off the GTC A/C units.
 Intrax loads were reduced with Laundry and Freezer off.
 The previous absorbed power that been reported in September and October are only
indicating the load flow during that specific period of time and conditions and it is varying
depending in seasonal times and usage requirement and these variable loadings have no big
effect on Generator sizing in comparison to Equipment nameplate full rated that has the
most influence on Generator sizing, protection system capability and cable sizing.
 The list includes only load ratings and description and none of the de-rating and design
factors been applied like minimum generator set load; maximum allowable step voltage dip
and step frequency dip; altitude and temperature; duty cycle; growth factor, fuel, phase,
frequency and voltage, harmonic and other factors that been left for designer to consider
when making the study for load analysis and Generator sizing.
 As everyone knows that Power use is not fixed and tends to grow over time. Therefore, any
generator set sizing exercise needs to take system expansion into consideration. Even with
sophisticated software solutions, the final decision on generator set size needs to be
tempered with judgment

Factors

1. Calculate the load size

2. Convert kW to kVA
3. Define your running requirements” If you’re
going to be using the generator as your main power
supply, you’ll need to size for 70-80% capacity. As
well as improving performance, leaving a 20-30%
safety margin will also allow for future power
requirements.
 4. Analyse site conditions and access

derating a generator is dependant on the manufacturing process design technique

and materials used . Different brands have different derating factors for estimating
generator output under non-standard ambient conditions. 

However, a general formula can be used to calculate close estimates for the output
levels. The standard derating formula states that for every 1000 ft above sea-level, a
gasoline, diesel, or liquid propane generator usually should be derated by 2–3% of its
standard output. In case of generators using natural gas, the derating factor is
typically closer to 5%. 

The wattages for each type of appliance are general guidelines

UP TO 7,500 WATTS Large Inverter
or Portable
GETS YOU: Refrigerator (700 watts), laptop (200 watts), five to 10 lights (250
watts), smartphone charger (20 watts), home security system (100 watts), TV
(100 to 150 watts), 10,000-btu air conditioner (1,000 watts). PLUS: Well pump
(1,250 watts), sump pump (900 watts), and gas or propane furnace (800 watts)
OR ONE OF THESE: 8-inch burner on an electric range (2,000 watts),
dishwasher (1,500 watts)

The calculators on this page are offered to assist in generating general estimations only.  In

most instances, there are numerous additional factors that should be accounted for (such as
altitude, site conditions, iron losses, motor efficiencies, etc.)

 Make a list of the items that need to be powered by the generator

 Make a note of the starting and running wattage of the respective items
 Calculate the total power requirements in KVA or KW

there are a few different ways of calculating power requirements:

 Single motor running 

 Multiple motors running simultaneously
 No electric motors

here's just a few of the benefits obtained by going through that process:

 No unexpected system failures

 No shutdowns due to capacity overload
 Increased longevity of the generator
 Guaranteed performance
 Smoother hassle-free maintenance
  Increased system life span
 Assured personal safety
 Much smaller chance of asset damage

if your new generator can't meet your specific requirements then it simply won't be
doing anyone any good because it can put undue stress on the unit and even damage
some of the devices connected to it.

Unfortunately, generator under sizing is one of the most common mistakes committed
by buyers.  Not only does it involve the risks of damaging your new asset (the
generator), but it can also damage other assets connected to it, create hazardous
situations, and even limit overall productivity of the unit and/or the business relying
on it.  If nothing else, the key thing to remember here is that more is always better
than less. 

Generators are typically designed to run most efficiently at or near sea level under
standard conditions of temperature and pressure (STP).

it is understood that STP conditions enhance generator power output due to

maximum air availability and desired flow quality of the fuel. Although designed to
bear 100% load during standard conditions, it is typically advised that generators be
run around 80% of their total capacity for maximum and continuous usage. In times of
emergencies, however, the generator can be pushed to deliver 100% output for critical
circuits. From a maintenance point of view, this does not overload a generator and the
life span of the genset is not affected negatively.  

A typical generator is ideally set to run at 80% of its capacity for continuous usage.In
an emergency, it may be utilized for 100% efficiency. 

Limitations with sizing programs, load uncertainty, leading power factor, motor starting
transients, harmonics, IGBT rectification, soft starters, VFDs, and UPS sizing can all play
a role in the stress created trying to size your own generator.

Sizing Program Limitations

Most sizing programs have not evolved with the generator technology of today.
Programs can analyze a few discrete loads and analyze a transient load with given pre-
load (like a motor start) fairly well. Most programs cannot accurately size a building
because they don’t support multiple load diversity factors or sometimes entering too
many loads in a single step creates a “false” condition. They also cannot model and
analyze non-linear loads accurately. Non-linear loads need harmonic analysis and
simple “rule of thumb” multipliers supplied by most programs are not adequate.

These programs have a hard time accurately sizing soft starters and UPS’s. Most
programs treat all soft starters exactly the same, regardless of technology. Also, UPS
technology can vary significantly depending on generator size. These details are not
usually accounted for in basic sizing programs.
Load Uncertainty

New Construction
It is hard to gauge what types of loads will be connected, what the anticipated load level
is, and what circuits are going to be connected. Depending on change orders during
construction, you could end up needing a completely different size of generator than
initially thought. This can lead to under sizing of the generator and possibly having to
restructure what loads are essential and what loads are optional in the event of an
emergency.

Load Growth
Do you have an aggressive growth plan? How certain is your business model? Would
you benefit from an expandable solution? Is paralleling a viable option for your
business? These are all questions that come up during generator sizing talks. Paralleling
is usually the best option for load growth over time, this allows your business to preserve
capital at the beginning and invest in more capacity over time.

Existing Facilities
Existing facilities looking to install a new generator need to know their power demand
inside and out before committing to a certain size of generator. This can be found by
analyzing billing history or using a power analyzer. Existing facilities should utilize all
historical measurement data to decide what size of generator would be good for their
specific application.

Leading Power Factor

Leading power factor can cause generator voltage issues. All 3-phase generators are
rated for .8 power factor. You can only reach full load current with these gens if you are
at .8 power factor or less. However, you cannot get full load amps or kW at a power
factor of less than .8. Having a leading power factor can cause self-excitation resulting in
voltage instability and over-voltage shutdowns. This needs to be accounted for when
choosing a generator.

Motor Starting Transients

Motor starting causes frequency dips. This can cause an issue with some loads. UPS’s
are most sensitive to frequency dips. You do not want more than a 15% voltage dip.
Some salesman will tell you a 35% dip is ok, because it only lasts for a fraction of a
second, but it can still cause issues. Some generators will only recover up to 90% if this
happens too often. Be sure to size your generator to handle motor starting transients.
You don’t want to be in an emergency situation and have the capability to run your
equipment, but not be able to start it. Oversizing the alternator on your motor can
mitigate some of these issues.
Harmonics

Non-linear loads caused by computers, UPSs, VFDs, battery chargers, or AC converting

to DC can all affect generator sizing. They can cause harmonic voltage distortion which
causes harmonic currents to flow through the alternator’s source impedance. Sizing can
be complicated by the alternator size and voltage and by the characteristics of your
facilities nonlinear loads. A harmonic analysis done by an engineer is better than
following any “rules of thumb” you may come across in regular sizing programs.

IGBT Rectifiers

A new type of rectifier is appearing in drives and UPS’s. Insulated Gate Bipolar
Transistor technology has come up as a new type of active power factor correction.
IGBT rectifiers can cause noise problems when they are the only load on the generator.
Connecting other loads seems to solve this problem. Be sure to take this into
consideration when sizing a new generator.

Soft Starters

Soft starters are an electronic, reduced voltage motor starter. They will produce
harmonics during their starting phase only. Distortion levels are impacted by the current
limit setting. Sequence starting can help mitigate the effects of harmonics. To avoid
voltage and frequency dips, always enable voltage ramping, this will create a soft
loading of the generator and limit transients.

VFDs & Regeneration

VFDs are seen as a rectifier by the generator. Voltage and frequency transients are not
the issue with VFDs, the issue is harmonics. Size for VFDs as if they were a non-linear
load and limit system voltage dips to 15% or lower. Regeneration becomes a topic of
discussion when cable elevators and cranes are involved. When the load is going down,
the drive becomes a break. Power must then be dissipated by a breaking resistor,
putting other loads on the generator, a unit mounted load bank, or not relying on the
generator as a break.

UPS Sizing

The issues that come with UPS’s depend on which type of UPS we are talking about.
Passive standby (formerly off-line) UPS’s create harmonics. This means that size is
used to control voltage distortion and loads should be stepped onto a generator if they
are large enough to cause a problem.

Line-Interactive UPS’s are sensitive to frequency variations, produce extensive

harmonics, and load steps from the UPS itself are often the main issue.  With both
passive standby and line-interactive UPS’s the generator kW rating should be the UPS x
5.
Double conversion UPS’s are the market norm for critical applications and higher power
ratings. These need no load stepping. You should size the alternator based on harmonic
content, consider battery recharge, and consider HVAC requirements. Assuming the
HVAC is on the generator you should size your generator kW rating as UPS x 2 to 2.5.

For more information on how to correctly size generators, watch our Generator

Sizing Webinar

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 
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Damien Olsen
Lead Generator Technician
Graduated from Idaho State University with a degree in Heavy Duty Diesel and Onsite
Power Generation. Damien is a master tinkerer and has been working on anything with a
motor since he was about six years old. Besides being a generator fanatic, Damien is