How to Choose a Prime Power Generator
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Heavy-duty applications require heavy-duty power. And, unfortunately, some of the most demanding industrial jobs are isolated from a central electrical grid.
In other instances, the task at hand is so critical that there isn't room for any utility power outages, like a hospital or cold-storage facility.
If you manage such an industrial or critical facility, then you need a constant source of electrical power that only a continous power generator can provide.
Continuous power generators, also known as prime power generators, serve as the primary source of electrical power for a given application and typically have an output ranging between 25 kilowatts and 1 Megawatt. They can run continuously (24/7) at variable and maximum loads to completely replace the utility provider, if necessary.
Prime-rated generators are not to be confused with emergency standby generators, which are meant for emergency power only. Typically, standby generators shouldn't be run for more than 200 hours per year and cannot permanently replace the utility provider. Continuous power generators, on the other hand, can run for an unlimited number of hours when properly maintained.
Prime power diesel and natural gas generators are available. We will discuss the pros and cons of each fuel type in more detail below.
Prime power generators are used as the main power source in a variety of industrial, medical, and heavy commercial applications.
Primary generator uses and applications go beyond the short list above. Any remote or off-grid need is a possibility.
Before making any continuous power generator purchase, you need to determine whether your application falls under the Environmental Protection Agency's (EPA's) Tier 4 regulations.
Tier 4 is designed to reduce emissions, such as nitrogen oxides and particulate matter, from diesel engines. If your application intends to use a diesel generator as its primary power source, then you need a unit that meets Tier 4 requirements.
However, using a natural gas prime power generator is environmentally cleaner and therefore does not fall under Tier 4. But, natural gas generators are
still
subject to their own special EPA compliance guidelines.
It's important to familiarize yourself with the full extent of Tier 4 regulations (diesel) and EPA guidelines (natural gas). Find more information in the EPA's Regulations for Emissions from Heavy Equipment with Diesel Engines.
Installing a prime power generator is an involved process that should be handled by a certified installer that specializes in prime power or industrial applications.
One of the most important aspects of the installation process is being aware of local codes and standards, especially air quality compliance boards. These typically supersede EPA requirements and can be more exacting.
The
South Coast Air Quality Management District
(SCAQMD) in southern California is a good example of a local/regional compliance board that has mandatory requirements governing engine emissions, such as those coming from prime power generators. Anyone installing prime power in that region, or regions with similar regulations, will need to familiarize themselves with those codes.
Because applications are so varied, in most cases your generator will need to be customized and built-to-order. Expect to undertake a thorough sizing and planning process with your manufacturer before anything gets installed.
In some instances, continuous power generators can be used alongside utility power to benefit everyone involved.
For example, the utility provider will supply a user with power up to a certain threshold. Once that threshold is reached (usually during peak usage), the user's generator will provide any supplemental power to make up the difference.
The utility will often pay the user for providing the additional power. It can also work in reverse with the generator running at a fixed output. If demand peaks, the utility provider makes up the power difference.
These load management deals allow the utility to more effectively predict and manage the amount of power supplied across the entire grid. They also minimize the electrical burden on both the utility and end-user while allowing both to meet their power goals.
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As mentioned above, there are pros and cons to both diesel and natural gas prime-rated generators. The table below compares the two types.
Diesel Prime Power
Gas Prime Power
Less maintenance/downtime More maintenance/downtime Smaller in size Larger in size Louder Quieter Can be more expensive due to Tier 4 requirements Less expensive; no Tier 4 requirements Diesel must be acquired and stored; not as readily available A gas line provides consistent fuel; can be interrupted in disastersUltimately, your continuous power generator fuel choice should reflect the needs of your application. For example, someone in the fracking business will have access to cheap natural gas. On the other hand, a military base far away from a gas line will obviously need to choose diesel.
Considering the application, along with the equipment/maintenance costs and current fuel prices, will help you make the right choice.
In order to operate continuously at peak performance, prime-rated generators should be on a regular maintenance schedule. You should base this schedule on NFPA 110 standards, manufacturer recommendations, and environmental conditions such as altitude and humidity.
Large companies might have an in-house engineer who can handle maintenance, while smaller ones can hire a local generator contractor. Some manufacturers also offer maintenance services themselves.
Typical maintenance includes:
The most important aspect of maintenance is to have a trained and certified professional doing it consistently. Never skimp on maintenance; otherwise, problems may creep up when you can least afford them.
Ultimately, installing a prime power generator isn't about choice; it's about necessity. If you need continuous, reliable power and don't plan on using the utility, then you need prime power.
Once you recognize this need, you should familiarize yourself with EPA regulations depending on which fuel choice is best for your particular application. Finally, ensure that a licensed professional installs and maintains the generator throughout its life.
If you're understandably hazy about this whole process, our in-house, factory-trained product experts are here to answer questions and make recommendations.
You can even discuss sizing, pricing, and financing by calling:
1 (800) 800-.
NEXT: Shop Prime Power Generators
By Jared G.
Generator Expert
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Table of Contents
- Introduction
- Trends
- Types
- Specs
- Features
- Choosing a Dealer
Generators keep you up and running. Generators can power items as small as a nail gun to large infrastructure like hospitals. From a business standpoint, they play a pivotal role in your ability to meet job requirements, regardless of bad weather conditions or power outages. Industries of all types need a power supply that is flexible, portable and available on demand. The following are a few industries where generators are commonly used:
Having a generator on hand is power at your fingertips. Generators allow you to have power wherever you are, whenever you need it. You can have a backup power source in case of natural disaster, inclement weather, or otherwise disrupted service. You won't have to worry about securing buildings and facilities, protecting perishable food items, or providing emergency services and healthcare.
Buying considerations
There are many things to consider when deciding on what type generator to purchase, such as size, use, and location. Careful evaluation of your requirements and the options available will help you pick the perfect generator for your needs.
There are electric generators, powered by batteries. The batteries are charged conventionally or by a small motor on the generator. When needed, the generator is moved to the work site and started to provide power. These generators are good for jobs that do not require a lot of torque and are of short duration, and that do not require more than watts.
Standby and portable generators utilize alternative fuel sources, such as diesel, LP, natural gas or propane and bi-fuel. These generators are more rugged, have greater strength and can operate for longer periods of time. These have the most possible uses with a wattage range of 500 watts to 50,000 watts.
You also have to consider where you are going to use the generator. Inside or outside? Will it be exposed to incremental weather? Do you have a need constant and consistent power or will it be used for short bursts of activity? Here is another area in which a trusted and reliable dealer can play an invaluable role. They can best guide your decision making process and ask relevant questions about where, when and how you will use the generator.
Working with a reputable dealer when deciding on what type of generator to purchase is essential. He or she can guide you through popular models with enough power based on a description of your industry, needs and probable uses. They have extensive experience with a wide variety of customers. That knowledge provides a significant advantage and possibility of savings or cost avoidance. They can help you get the power you need without paying for power you may not ever use.
Cost
Price ranges vary considerably. You can purchase an electric generator with sufficient power for short term use for as little as $1,500. Conversely, a standby backup generator with enough power to run your essential home devices (water heater, air conditioner, and refrigerator, for example) runs about $22,000 brand new. Generators large enough to run industrial warehouses with freezers to prevent spoilage can be as much as $125,000. Heavy duty units for critical infrastructure needs, such as hospitals, can cost hundreds of thousands of dollars.
This purchasing guide will identify types and trends in generator use by industry, their specifications, and advanced features that enhance performance. It will also tell you what questions to ask a dealer in order to purchase the right kind of generator with sufficient power to meet your unique and specific needs.
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