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How to Size a Generator for a Factory in Nigeria

Sizing a factory generator by adding nameplates and picking the next size up often leads to a set that is too large and runs at low load, or too small and trips on motor starts.

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Industrial diesel generator set in an outdoor enclosure

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A sound size comes from the loads that run together, the largest motor start, the site's heat and a sensible allowance for growth.

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Steps

List every load with its kW or hp rating and whether it is single-phase or three-phase
Mark which loads run at the same time and which only run occasionally
Find the largest motor and how it starts: direct-on-line, star-delta or soft starter
Add the simultaneous running load, then allow for motor starting
Apply the generator's power factor, usually 0.8, to convert kW to kVA
Add an allowance for future growth and check the result against standard sizes

Things That Raise the Size You Need

Large motors started direct-on-line
Welders, compressors and other cycling loads
High ambient temperature, since sets lose output in heat
Sensitive electronics that need a stable supply
Planned additions to the plant

Things That Let You Go Smaller

Soft starters or variable-speed drives on large motors
Staggering motor starts rather than starting everything at once
Load shedding for non-critical equipment during outages

Quick Check

Aim for a typical running load of roughly half to three-quarters of the set's rating
Avoid very light loads for long periods, which wastes fuel and can harm the engine
Ask the supplier to confirm the starting capability for your largest motor

Frequently Asked Questions

Should I size the generator to the full connected load?

Usually not. Size to the loads that run together, plus the largest motor start and a growth allowance. Sizing to every nameplate often gives an oversized set.