While getting a new or replacement generator is sometimes a critically urgent task for your operation, you should never rush generator sizing. This important exercise ensures that you match the best generator for the load you need to handle, allowing for growth too.
- The Basics of Generator Sizing
On a basic level, sizing simply involves choosing an industrial generator with enough power – you’re likely choosing from a range of 50kW to more than 3 megawatts – that will handle the your operation’s load. If you have already recorded the starting and running wattage of all the equipment your generator will be called on to support, this becomes a simple math problem. Operations managers run into a few problems here, including not knowing all the equipment that’s being powered, guessing at the wattage (check the equipment’s ID plate, owner’s manual or measure it yourself), and not thinking about tomorrow’s needs. If you’re planning an expansion or simply want to be prepared for future growth, consider selecting a power output that’s a bit more than you’re currently running. If you have an extremely complex operation or a site subject to extreme altitude or temperatures – both of which impact load balancing – you can find engineering consultants capable of helping with the generator sizing. One more important detail: generators are at their best when they’re consistently running at 70 to 80 percent of capacity. Keep that in mind when doing the math. - The Dangers of Failing to Size Appropriately
Shortsighted generator sizing leads to imbalanced loads, which can cause a wide range of operational misfires. A generator supporting too large a load will exhibit poor fuel efficiency and more than likely experience system failures that can damage both the generator and the supporting equipment. On the other hand, when generator sets run well below their capacity, they’re subject to wet stacking. That’s a fancy way of describing how fuel can leak when there is no or little load to support. An automatic load bank can help remedy this issue if it’s an ongoing problem. It’s important to know that improper generator sizing can lead to equipment malfunctions that pose serious safety threats, so the gamble of improper sizing is greater than merely damaging equipment or wasting fuel.
In the same way that choosing too small of a generator can plague your operation with a number of problems, choosing the largest generator available isn’t just cost prohibitive, but it’s also harmful to your equipment and potentially your workforce, too. Take the time to make generator sizing a serious exercise that takes into account both today’s operational needs and tomorrow’s possibilities.
To make shopping for generators and other equipment easier, download our free buying guide. Then, be sure to chat with one of our experts before making your selection. We are here to help you get the best equipment to serve your needs and always at the best prices.
