GENERATOR SET SIZING FOR FWPH AT SPL POLYMERS LTD, MANALI PLANT

GENERATOR SIZING FACTORS:

Generator capacity (kVA) is determined no only by total load, but also by motor size, configuration,
starting sequence and possible motor-starting aids.

Data on load to be driven by the DG set to be installed in the FWPH (NEW) for make up water tank
replenishing using submersible pumps:

 Usage rating of DG set STAND-BY RATING: 500 HOURS PER YEAR AT 100% LOAD OUT
OF WHICH 300 HOURS IS CONTINUOUS RUNNING MODE.

 Starting sequence Immaterial since both motors are of same capacity

 SKVA rating (>15HP <=40HP) Locked rotor kVA requirements: 5.3 mean value (see Table)

 Starting aid WYE start and DELTA starter supplied by KISHORE PUMPS

 Voltage dip allowed Maximum 20%. Calculations to be done also for 10%

 Kirloskar DG set chosen KeP171W with 6R1080TA

 Recommended rating KVA Continuous: 128 KVA (100KW) Stand-by: 138 KVA (110KW)

 Alternator efficiency 86.5%

NEMA Code Letter KVA/HP with locked rotor(SKVA)

A 0-3.14

B 3.15-3.55

C 3.55-3.99

D 4.0-4.49

E 4.5-4.99

F 5.0-5.59

G 5.6-6.29

H 6.3-7.09

J 7.1-7.99

K 8.0-8.99

SIZING OF DG SET FOR CHECKING SIMULTANEOUS RUNNING OF MOTORS Page 1

L 9.0-9.99

M 10.0-11.19

The starting KVA required by a motor starting at full voltage is determined from the nameplate on the
motor or from the manufacturer.

In general it is accepted that small motors requires higher starting KVA than larger motors. Standard 3
phase motors often have these locked rotor codes:

* less than 1 hp: Locked Rotor Code L, 9.0-9.99 KVA

* 1 1/2 to 2 hp: Locked Rotor Code L or M, 9.0-11.19

* 3 hp : Locked Rotor Code K, 8.0-8.99

* 5 hp : Locked Rotor Code J, 7.1-7.99

* 7.5 to 10 hp : Locked Rotor Code H, 6.3-7.09

* more than 15 hp <40 hp : Locked Rotor Code G, 5.6-6.29

* more => 40 hp : Locked Rotor Code F, 5.0-5.59

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CALCULATION SHEET FOR GENERATOR SIZING FOR MULTIPLE MOTOR STARTING ON LOAD

CUSTOMER: SPL POLYMERS LTD

PROJECT: MANALI PLANT AUGMENTATION

STUDY BY: K R MOHAN

DATE: 10-02-2008

APPLICATION DATA: DG SET FOR STAND-BY RATING POWER (500 HOURS PER YEAR ON LOAD)

PRIME MOVER: DIESEL GENERATING SET

SPECS: 415V, 3P, 50 Hz 0.8 Pf

LOADS:

LIGHTING LOAD : NIL SINCE LIGHTING IS SOURCED BY BOARD POWER

NO MOTOR LOADS : NIL SINCE CHARGER AND SOCKET POWER IS SOURCED BY EB POWER

MOTOR LOADS : 2 Nos OF 30Kw (40 HP) STAR/ DELTA STARTER DRIVEN SUBMERSIBLE PUMPS

MOTOR EFFICIENCY :86.5%

STARTING hp NEMA CODE STARTER V DROP% EFFICIENCY KW

SEQUENCE

01 40 F (5.3) STAR/DELTA 20% / 10% 86.5 30

02 40 F (5.3) STAR/DELTA 20% / 10% 86.5 30

DG SET SELECTED: 6R1080TA (125 KVA, 3P, 415V, 50 Hz 1500RPM)

SIZING OF DG SET FOR CHECKING SIMULTANEOUS RUNNING OF MOTORS Page 5

DG SIZING: MOTOR 1 MOTOR2

A. STARTING KVA (SKVA) 40HP 40HP

B. NEMA CODE F F

C. SKVAR/ HP AS PER CODE 5.3 5.3

D. SKVA/HP x MOTOR HP (A x C) 212 212

EFFECTIVE SKVA:

A1. ALL MOTORS RUNNING 0 KW 30KW

B1. ALL MOTORS RUNNING /STARTED 30KW 60KW

C1. (A1/B1) x 100 0% 50%

D1. COMPENSATION FOR MOTOR ALREADY STARTED (SEE GRAPH) 1.0 1.07

E1. D x D1 212 SKVA 226 SKVA

F1. STARTER FACTOR (STAR/DELTA 0.33) SEE TABLE 0.33 0.33

G1. EFFECTIVE SKVA = E1 x F1 70 SKVA 74 SKVA

H1. ACCEPTABLE VOLTAGE DROP IN ALTERNATOR 10% 10%

I1. SKVA FOR 10% DROP IN VOLTAGE FOR MODEL 6R1080TA 74KVA 74KVA

J1. SKVA FOR 20% DROP IN VOLTAGEFOR MODEL 6R1080TA 167KVA 167KVA

(REFER TABLE ENCLOSED FOR SKVA FOR VOLTAGE DROPS)

CONCLUSION: FROM THE ABOVE CALCULATION SHEET IT IS CLEAR THAT FOR MODEL NO 6R1080TA,
ASSUMING THAT A MAXIMUM DROP OF TERMINAL VOLTAGE IN THE ALTERNATOR IS 10%, THE SIZING IS
JUST ABOUT RIGHT FOR STARTING ONE KISHORE PUMP OF RATING 40HP WHEN ANOTHER KISHORE
PUMP OF EQUAL RATE IS RUNNING. THE POINT TO BE NOTED IS THAT EVEN THOUGH THE RATING OF
THE MOTOR IS 40 HP THE ACTUAL FULL LOAD OF THE SUBMERSIBLE PUMP WOULD NOT BE GREATER
THAN 35 HP AND SO THE SELECTED SIZING OF THE MODEL OF DG IS GOOD ENOUGH FOR
SIMULTANEOUS RUNNING OF TWO MOTORS WITH SEQUENTIAL STARTING ON WYE START AND DELTA
RUN STARTERS. FOR 20% VOLTAGE DROP, IF ACCEPTABLE (INDUSTRIAL STANDARDS ACCEPTED FOR
MOMENTARY VOLTAGE DIP IS 20% WHICH WOULD NOT BE LOW ENOUGH TO TRIP MOTORS OR
RELEASE CONTACTORS) WOULD MAKE THE OFFERED SIZE OF DG MORE THAN ADEQUATELY SIZED.

SIZING OF DG SET FOR CHECKING SIMULTANEOUS RUNNING OF MOTORS Page 6

K R MOHAN

ELEGANT ENGINEERING WORKS (P) LTD

CHENNAI - 89

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