Generators for industrial purposes come with different configurations and functions. It is imperative that customers should know the details of generators before they go for rent or purchase, such as running costs, fuel efficiency, fuel tank capacity, power factor and so on.
The most common generators used are diesel and gas generators. The diesel generators are expensive than gasoline generators, but in the long run it is advantageous because the maintenance cost is less and the fuel efficiency is better. Some known generator manufacturers are Kirloskar, Cummins, Sudhir and Mahindrapowerol.
Let's see some of the parameters that you should consider before hiring or buying an industrial generator.
The most common generators for small and medium-sized industries are 82.5 Kva, 125 Kva, 250Kva, 500Kva. Usually it's a misconception that the smaller size generator performs better, but in fact, the other way around is. The bigger the size better is the generator's performance. Selecting smaller size generators can damage devices that draw power from generators.
By summing the power out of your devices, you can calculate the total power consumption and determine the size of the generator. You can consult a certified electrician to analyze your requirements or determine start and run current. You can also use the equipment manual to check the start and run current for industrial tools and equipment. When selecting industrial generator factors as primary impact assessment, load combination and maximum power should be considered.
Fuel tank capacity
Storage capacity is determined by how long time generators may need to run, also known as Run-Time. The engine run time depends on fuel efficiency and fuel tank size. The fuel storage capacity of the above-mentioned generators is 145 liters, 290 liters, 450 liters, 690 liters.
Fuel consumed per hour
Generators larger in size are more effective when comparing their liters per kVA, the same with liters per hour. In comparison with petroleum and natural gas generators, a diesel engine has better fuel efficiency. But note that a diesel engine works better under load, it should not work less than 50% load.
The diesel speed varies between countries, in India the diesel price is 55-60 liter. If you consider 85kv capacity engine, fuel consumption per hour would be 21 ltrs h. So the cost you carry to run a generator of 85Kva per hour would be Rs 1100-1200.
Similarly, you can calculate the cost per hour for other operating engines. For example, the consumption of 125Kva-31Ltrs h, 250Kva-58Ltrs h and 500Kva-107Ltrs h.
For better fuel efficiency, you need to check the diesel standard for parameters such as cetantal, sulfur levels, fuel viscosity, gravity, distillation, flash point, pour point, water and sediment, carbon balance, and so on.
Power factor is a device for calculating electrical system efficiency. It can be defined as the ratio of kVA to kW is drawn by an electric load. The load's lowest power factor is 0.8, it is the minimum limit for which diesel generator is to be driven. Generators operating under 0.8 pf will consume more fuel. Diesel engines are expected to incur maintenance only after operation at 1800 rpm for 12,000 to 30,000 hours.
Why use diesel generator?
Few advantages listed for diesel generators,
Diesel generators are economically viable solutions
Low maintenance due to low heat output and lack of spark plug Auto-ignite
Powerful and reliable power source, then AC
Smaller emissions of smoke
Quiet operation with minimal noise
Best source of direct current Direct current
Do's and Dont's for handling diesel generators
To achieve low maintenance costs and better durability o the generator. Use the following tips:
Do not attempt to use the power cord cable as the distance causes the power to break down.
Make sure all contacts, nuts and bolts are properly tightened.
Use suitable wiring to avoid power leakage
Suitable load distribution per phase.
Make regular fuel level checks.
Do not start the generator at load.
Avoid adding any acid to the battery. For setup, prefer to use distilled water.