Energy and Power

Important generator set

(genset) rating considerations
By Edvard January, 30th 2015

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Rating Definitions
A generator set (genset) consists of an
engine and a generator and it is best to
consider each of them as a system.
Individually, each has unique characteristics,
but together these qualities have a
significant impact on the performance and
sizing of the genset system.

Important generator set (genset) rating considerations

(photo credit: powergenenterprises.com)

Capabilities of both engine and generator

are considered individually and collectively
when selecting generator sets. Engines
produce brake horsepower (or kilowatts)
while controlling speed or frequency.

Generators influence engine behavior, but

are primarily responsible for changing engine
power into kilovolt-amperes (kVA) and
electrical kilowatts (kW). They also must
satisfy high “magnetizing current” draws
(kVAR), or transient conditions from electrical
equipment.

Normally, a generator set is

furnished with a generator which
matches the engine output
capability.

Engines are sized according to the actual

power in kW required to meet the needs of
the facility. The generator, on the other hand,
must be capable of handling the maximum
apparent power which is measured in kVA.
The actual power can be identified in several
ways. It can be calculated by adding the
nameplate ratings of the equipment to be
powered by the generator. If this is done, the
efficiencies of the equipment must also be
considered.

Genset nameplate (photo credit: vzaudit.zabatt.com)

The actual power can be determined by

performing a load analysis on the facility.
This involves making a survey of the power
requirements over a period of time.

ekW = pf x kVA

bkW = ekW / eff + Fan Demand

Where:

kVA = kVA output of generator

pf = power factor of connected load
ekW = electrical power (electrical kW)
bkW = engine power (brake kW)
eff = generator efficiency

When kW is qualified as neither electrical

(ekW) nor brake (bkW), it is important to
clarify between the two when performing
calculations or product comparisons.

Engine/Generator Set Load Factor

Load factor of a generator set is used as one

criterion for rating a genset. It is calculated
by finding the product of various loads:

Load Factor = % of time x % of load

% of time = time at specific load / total
operating time
% of load = specific load / rated load

Extended idling time and the time when the

generator set is not operating does not enter
into the calculation for load factor.

Example //

For example, assume a facility has a

genset rated at 550 kW and runs it two
hours a week. During those two hours,
it runs at 400 kW for 1.5 hours. Find
the load factor. The formulas reveal the
following:

% of load = 400kW / 550kW =

0.73
% of time = 90 min. / 120 min. =
0.75
Load Factor = 0.73 x 0.75 =
54.75%

This load factor would indicate that the

genset could be used as a standby
rated genset because it meets the load
factor and other criteria of standby.

Power rating definitions for generator

sets are based on typical load factor,
hours of use per year, peak demand
and application use. For example
Caterpillar genset ratings for
emergency standby, standby, prime and
continuous power are listed.

Emergency Standby Power

Typical usage of 50 hours per year with a

maximum of 200 hours per year. Typical
variable load factor of 70%.

Standby Power

Maximum usage 500 hours per year, up to

300 hours of which may be continuous
running with varying loads. No overload is
available. Rating is equivalent to Prime
+10%. Load factor maximum is 70% of
Standby rating.

Prime Power

Unlimited hours of usage. Load factor

(70% maximum /80% if no extra cost) of
the published Prime power over each 24
hour period.

10% overload limited to 1 in 12 hours but not

to exceed 25 hours per year. The 10%
overload is available in accordance with
ISO 3046-1 (2002). Life to overhaul of the
engine is dependent on operation as outlined
in ISO8528 (2005) and time spent during
operation above
100% load may affect the life to overhaul.

Continuous Power

Unlimited hours of usage. Load factor

100% of the published Continuous Power.

Generally, as ISO 8528 (2005) Continuous

power. Note: Operating above these
rating definitions will result in shorter life and
higher generator and engine costs per year.

The International Standards Organization

(ISO)

ISO 8528-1 (2005) defines three types of

duty:

1. Continuous Operating Power (COP)

2. Prime Running Power (PRP)
3. Limited-Time running Power (LTP)

1. Continuous Operating Power (COP)

Continuous operating power is the power a

generator set can operate at a continuous
load for an unlimited number of hours
under stated ambient conditions.
Maintenance according to the manufacturer
must be followed to reach these standards.

2. Prime Running Power (PRP)

Prime running power is the maximum power

a generator set has during a variable
power sequence for an unlimited number
of hours under stated ambient
conditions. Maintenance according to
the manufacturer must be followed to reach
these standards.

3. Limited-Time Running Power (LTP)

Limited-time running power is the maximum

power that a generator set delivers for up to
500 hours per year under stated ambient
conditions. Only 300 hours can be
continuous running. Maintenance according
to the manufacturer must be followed to
reach these standards.

Specifications are often stated in ISO terms

and standards. Table 1 shows ISO genset
ratings and correlating Caterpillar genset
ratings.

Generator Set
Ratings
ISO Caterpillar
ESP Emergency
Standby Power
LTP Emergency
Standby
PRP Prime
COP Continuous

500KVA Cummins Diesel Generator set

cold start/Backfire

500KVA Cummins Diesel Generator set

cold start/Backfire, been stood for a while
and the temperature was -20º C. The
controller shut it down after it revved up at
the end.

Cant see this video? Click here to watch it on Youtube.

Reference: Electric Power Application,

Engine and Generator Selection – Caterpillar
(Download HERE)

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MORE INFORMATION

Edvard Csanyi

Electrical engineer,
programmer and
founder of EEP.
Highly specialized for
design of LV/MV
switchgears and LV high power busbar
trunking (<6300A) in power substations,
commercial buildings and industry facilities.
Professional in AutoCAD programming.

8 Comments

My boss is looking to get a

new genset for our
Rhianna workplace, and I haven’t
Hawk spent a lot of time with the
N
NOOV
V 2277,, 22001188
old one, so I didn’t know
that brake horsepower was
the same as kilowatts. It’s
good to know that engines
are sized according to kW
required, and I’ll definitely
make sure that my boss
knows what our kW needs
are before going and
looking at systems. Your
translation of different
symbols in terms of load will
really help, as well, and I’ll
be sure to pass that on to
him.

(reply)
(reply)

I am an American engineer
consulting in Indonesia. We
Jeremiah need a reliable diesel
Ridenour generator to supply constant
FFE
EBB 1199,, 22001188
current of 3 phase supply.
We are processing palm
syrup on a remote island
and need a very reliable
unit.

It will be off during part of

the night when we are not
processing and a small
5000 watt gas generator will
supply electric to the lights.

Our demand is around

40KVA which is running a
30KVA refrigeration
system,750 watts of lights,
and around another 10 kva
in water well pumps and
packaging equipment which
are not completely defined
yet.

How much over the 40KVA

should I specify for safety?

Also can you recommend a

unit with the best diesel
usage per hour, as diesel is
not easy to get out there.
Are there units that cycle
based on demand thereby
saving fuel?

In your experience what is

the most reliable brand of
engine and generator
combination?

Thank you appreciate your

help !

Please email me if you can

as I will not be checking this
site.

jeremiah@wisesolutions.net

(reply)
(reply)

Dear Sir,
How can I calculate mass
Mominul flow rate from a generator
Islam data, Such as
JJA
ANN 0077,, 22001188
CATERPILLAR G3516H…..
From technical data,
Exhaust gas flow rate
m3/bkw-hr = 3.81

If you know, please help

me,
1m3/bkw-hr = kg/hr??

(reply)
(reply)

Thanks very much I just

wana to know about & will
Abraham send questions.
N
NOOV
V 1133,, 22001155

(reply)
(reply)

@Juan David,

Faraz You have quoted two cases

Muhammad with changed PF & raised a
Fateh
S
SEEP
P 1100,, 22001155
few queries against the
original formula.
Please note that the Engine
power will be prime mover
of shaft, which will generate
REAL power.
It is the REACTIVE power
which has increased in
case-2 thus increasing the
KVA from 100 to 266 but
the REAL power is still the
same (i.e 80KW).

Since the REAL power in

both cases are same
therefore the Engine size
can also be same
irrespective of the the
change in KVA ratings.

@Edvard,
While we are working in
industries it is difficult
sometimes to go back to
our old university books due
to time constraints &
laziness :p . But you are
doing a splendid job in
refreshing many of our
concepts on daily basis in
quick time.

The only thing which

bothers me is that i donot
see any article
written/published here by
any other user. Have you
restricted its publication or
is it that the users
themselves are not writing
anything??

BR,
Faraz

(reply)
(reply)

it’s very good, but may i find

setting calculation example
Essam for the different functions of
Drar the generator?
FFE
EBB 0011,, 22001155

(reply)
(reply)

Great information Edvard. I

am also interested in
Richard information regarding typical
Handley fault levels for gen sets in
JJA
ANN 3311,, 22001155
particular single phase
diesel generators.

(reply)
(reply)

Thanks for great paper, Is

very important to keep in
JUAN touch with our colleagues.
DAVID
HENAO
RUIZ Another way to see
JJA
ANN 3300,, 22001155 mechanical power becoming
electric power

Beginning with:

ekW = pf x kVA
bkW = ekW / eff + Fan
Demand

lets play an example

bkW =?
ekW=80
eff =0.7
Fan Demand usually can be
about … = 0.1* bkW

Then

bkW = (ekW / eff ) + 0.1*

bkW

(1-0.1) * bkW = ekW / eff

bkW = ekW / (eff * 0.9) =

80/(0.7 * 0.9) = 126.98

if pf=0.8 then

ekW = 80
pf=0.8
kVA=100, can be feeded by
127bkW :)

but it if pf=0.3 then

ekW = 80
pf=0.3
kVA=266, NOT can be
feended by 127bkW ****** :|
********

So this is not right that

same power makes so big
kVA with a same kKW
Common sense means this
is impossible; to produce