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Generator sizing application-guide practice9 min read

Worked Example: Genset Sizing — When Running Load Governs Over Motor-Starting Dip

Two independent generator-sizing checks — steady running capacity and motor-starting voltage dip — with running load turning out to be the larger, governing requirement in this case.

Scenario

Linear (steady) load300 kW at 0.85 power factor
Non-linear load100 kVA, with a 1.5x non-linear derating factor
Largest motor starting load240 kVA starting kVA
Generator subtransient reactance (Xd'')0.15 p.u.
Maximum acceptable voltage dip15%

Step-by-step calculation

Step 1: Compute running capacity requirement

runKva = (linearKw / PF) + nonlinearKva x derateFactor
(300 / 0.85) + (100 x 1.5)
runKva = 352.9 + 150 = 502.9 kVA

Step 2: Compute the generator size needed to limit motor-starting voltage dip

dipReqKva = (motorStartKva x Xd'') / (maxDip% / 100)
(240 x 0.15) / 0.15
dipReqKva = 240 kVA

Step 3: Compare the two requirements and find the governing one

RequirementSize neededGoverns?
Running load502.9 kVAYes — larger of the two
Motor-starting dip240 kVANo

Step 4: Estimate fuel consumption and hourly running cost at the recommended size

Using the conventional 0.8 power factor genset rating basis.

kW at full load = recommendedKva x 0.8 fuelRate = SFC x kW
kW = 502.9 x 0.8 = 402.4; fuelRate = 0.25 x 402.4
Fuel rate = 100.6 L/hr -> $120.71/hr at $1.20/L

Result summary

CheckRequirementActualStatus
Governing sizing requirementn/a (this is the finding)Running load (502.9 kVA) exceeds motor-starting requirement (240 kVA)✓ PASS
Recommended generator sizen/a (this is the result)502.9 kVA✓ PASS
Running load (502.9 kVA) is more than double the motor-starting requirement (240 kVA) in this scenario, so the generator is sized for steady-state capacity, not starting transient — the opposite of many smaller sites where a single large motor's starting current dominates sizing.

Key insight: Which requirement governs generator sizing depends entirely on the ratio between total connected load and the largest single starting load — a site with modest continuous load but one large motor often has starting dip as the governing constraint, while a site with substantial baseline load (like this one, with 300 kW linear plus derated non-linear load) more often finds running capacity is what actually drives the sizing decision. Always compute both, since assuming one governs without checking can lead to an undersized unit.

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Frequently asked questions

Why does non-linear load get a 1.5x derating factor instead of being added directly?

Non-linear loads (VFDs, UPS input rectifiers, switch-mode supplies) draw distorted, harmonic-rich current that a generator's alternator has to handle less efficiently than the equivalent linear kVA — the derating factor accounts for the generator needing extra headroom to serve the same nameplate kVA of non-linear load without overheating or excessive voltage distortion, a widely used sizing practice from generator application guides.

What would make the motor-starting dip check govern instead?

A larger single motor relative to total site load — for example, the same generator serving a lighter 100 kW linear/non-linear baseline but starting the same 240 kVA motor would find dipReqKva (still 240 kVA, since it only depends on the motor and generator reactance) now exceeds a much smaller running-load requirement, flipping which check governs the final size.

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