lexus31rus said:
... So, is there any formula, I can use for estimate generator loads in the future? ...
first a couple of basics:
1. The generator is rated at 650kw. That is the rating of the driver. If the gen has a 615kw load on it, the throttle will be wide open. If more load is added, the driver (engine) will slow down. This has nothing to do with the ratings of the alternator end.
2. the generator is rated for "Standby" duty. Thsi means the mfg has put together as thin a package as they can as still get it to put out 650kw. Usually this means one must use a very stable load bank and slowly tease the load up to 650kw. They won't put out anything close to 650kw continuous. For example, if the gen were loaded to 550kw and you started a 125hp motor (that's 93kw) the driver would stumble and probably even trip off - under freq.
If the gen were loaded to 550kw and you turned on 100kw of tungsten lighting - the gen would probably trip.
3. Part of the standby rating also includes time under load. This one you will have to look up. It could easily be rated for no more than 10 hours per month. Yep - that little.
So this is a good place for
Rule 1: For standby rated machines: If the gen is to be run more than actual emergencies load to only 75% continuous. If the gen is run only during actual emergencies, load to only 80%. These are real power numbers - KW.
Rule 2: If you are starting large motors, say .3x to .5x of the gen rating, then that may be all the gen can do - unless one employs some crafty load sheding.
Now let's look at the alternator end. The KVA rating is essentially the heat rejection capability. The alternator is rated at 978A at an 80% power factor -
lagging. That is because for the last 150 years the standard industrial load was mostly motors, which are inductive, which is called lagging power factor. Don't confues this "80%" with any kind of a derate for the driver - it is not. It is a measure of how much of an inductive load the alternator can take without overheating. So the .8pf rating tells you that with any industry standard motor load, the alternator will not overheat. The driver will run out of power first.
So now you should see that the gen is driver limited - unless there are really weird loads.
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Now let's look at the distribution - that's everything from the alternator terminals out toward the loads. Starts with the first circuit breaker, and the conductors out to the panels.
First I have no clue why the first CB is an 800A. That is nutzz - completely bonkers.
Unless you have special stuff, the circuit breakers are only rated to carry 80% continuous. There's that pesky "80%" again. Nope it is not related to power factor or driver derate. So with an 800A CB for the first overcurent protection, the most continuous load would be .8 x 800 = 640A, which is 530kw - less if the loads are standard motors - maybe 90% of that or 480kw. If one needed to run the gen WFO for an emergency - couldn't do it, the CB would trip. The norm would be a 1200A CB.
But you said the existing load was 235A. Assuming a .9pf that's 175kw. So the existing install is a 650kw genset, limited to 480kw bythe distribution, and only has a 175kw load on it. Stranger and stranger.
That is as much as I can infer from what you have told up - and I could be alll wet.
lexus31rus said:
... In my position I just want to be able to answer my boss question "Hey, can we put this equipment on the emergency power?" and be able to support it with calculations.
First, is this a creeping thing where every now and then the boss wants to add load to the Emergency? If so, "Does the equipment meet the criteria for needing to be on the "Legally Required Emergency Standby" generator? If "No", then, "No".
Or is this a redesign of the emergency standby system? If this is so, then you need to learn how to do load studies, protective relays, NEC compliant design - because you are the engineer of record.
I can give you some hints:
The concept that an Emergency generator can stumble or quake on startup is not a good idea. Emergency generators need to be pretty rock solid. Some emergency loads require that the gen be running and loaded within 10 seconds from power out.
Figure out why this has a 650kw gen. The loads are such that a Standby rated 250kw would have done fine - unless there are a couple of 100hp motors. I can't open your fire pump sheet so I don't know what you have.
Wonder why I'm not giving you any better (more definitive) answers? Designing robust, stable, cost effective, emergency systems is difficult enough if one is standing there. It's impossible from my side of your keyboard.
So sayeth the Worm