When to Choose a Diesel Generator for Your Business

If your business requires electrical power that is continuously reliable, long runtimes, or backup power (for when your normal power supply is unavailable), then buying or leasing a diesel generator is often the next step.

The right time to buy depends on the current electrical power your plant demands and plans for future growth and expansion. It also depends on your tolerance for downtime caused by power outages.

How will a diesel generator integrate with your current power supply?

In the context of manufacturing or plant management, a diesel generator could provide all of your power requirements, supplement your existing grid power source, or provide backup/standby power for when grid power is unavailable.

When to choose a diesel generator over alternative power sources

If your main requirements are fuel-efficiency, robustness, comparatively low maintenance requirements and reliability, then a diesel generator could win over, say, a petrol generator.

• Fuel efficiency. As diesel fuel has a higher energy density compared to other fuels, a diesel generator offers a more powerful output whilst using less fuel.
• Diesel generators are built to withstand the elements and are better suited to outdoor and extreme weather conditions.
• They generally require fewer repairs and maintenance, which will reduce costly downtime.
• Diesel generators are renowned for their ability to run for long periods of time without stopping.

But if you have requirements that are mostly about noise, size, and environmental friendliness then other options should be on your radar too.

• Diesel generators are often noisier than newer models with more efficient fuel systems. There are ways to reduce noise.
• The running costs of a diesel generator are higher compared to petrol counterparts.
• Diesel generators tend to be larger and heavier than other generators and take up more space.
• Diesel engines can produce harmful emissions including nitrogen oxide and particulate matter which can be detrimental to the environment and to health. Provided this is mitigated against, they are perfectly safe.

How to decide what power output you need

Your power requirements are calculated by adding together the number of watts used by your current equipment, when running simultaneously.

The amount of power being generated at any one time is called the “load”. Once you have determined your power output requirements, you will have a better idea of what kind of load your generator needs to output.

You also need to look at minimum and maximum load requirements. This is important, because a generator that is not “loaded” correctly, whether too lightly or too heavily, will have an impact on the machine in the long run.

Minimum load is needed when your plant is running during off-peaks times and maximum when things are at their busiest, with all your equipment needing power.

How to avoid underloading your generator

Underloading a generator is when a generator operates with too little demand, generally below 30% of its rated capacity. Underloading can cause several issues, including carbon build-up, excessive wear and tear and oil leaks. Aiming to run a diesel generator around 60-75% of its maximum rated load, is a solid guideline to adhere to.

Smaller generators, typically below 100kVA, have a greater load acceptance capability in the region of 70 to 100%. Larger machines up to 2.5mVA have less capability on first step acceptance in the region of 50 to 65%.

Apart from the purchase cost of a generator, what other costs are involved?

Diesel generators, like any long-running machines, require regular servicing and maintenance. This is to avoid faults before they occur, keep machines running at optimum efficiency, and reduce the risk of dangerous malfunction. It is therefore imperative to factor in regular service and maintenance plans.

You should factor in several maintenance and services checks throughout the year to keep your machine in excellent operational order. Weekly, monthly and quarterly maintenance checks are recommended and can be provided by generator experts such as Rehlko.

See also: diesel generator maintenance

What are the practical considerations of installing a diesel generator?

You will need to consider access to your plant for installation and maintenance. For example, whether you choose an external (outdoor) canopied generator set, external drop-over enclosed generator set (for special noise applications) or require an external containerised generator set and plant room installation, all choices will require different levels of access to get the machine installed safely.

Industry-standard noise levels …

Cooling requirements …

Cross flow ventilation …

When it comes to the type of installation, cost, lead time, practicality and future maintenance all play significant factors before making that final choice.

So, is now the right time to buy or hire a generator?

Consider the following questions, to help guide you in your decision-making process.

1. Does your business or plant have ongoing power requirements that are not always met by grid power?
2. Does your business rely on continual power? Or can you tolerate occasional downtimes and outages?
3. Do you have expansion plans which will require more power in the medium to long term?
4. Does your plant run continuously or nearly all the time?
5. Would you be able to commit to ongoing maintenance and servicing?
6. Do you have (or could you create) adequate space to install and house a diesel generator?

If you answered “yes” to most of these questions, then now is definitely the right time to start investigating. They can help steer your decision towards or away from diesel generators as a source of prime power or backup power for your business in the near future.

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