In modern times, diesel generators have become the ideal choice for backup power supply in all industries due to their stability, reliability and sustainability. However, many enterprises do not realize the importance of power to them until they lose it. If your business is located in an area where power outages are frequent, you will know the inconvenience caused by a sudden power outage and the damage caused by a power outage, especially in harsh weather conditions or tight power grids. As a result, more and more companies are choosing to configure standby diesel generators to provide adequate power to their facilities during power outages to avoid forced shutdowns due to power shortages. However, when purchasing diesel generators, it is important to ask yourself, “How much power do my business need for diesel generators?”
Technically, the power of a diesel generator is independent of its physical size. Generally speaking, the power of a diesel generator, also known as its generator capacity, refers to the amount of electricity it can generate within a certain time to start and maintain office equipment or production and manufacturing equipment. In other words, a diesel generator with more power generates more power than a generator with less power. Generally speaking, power is in watts or kilowatts.
Generally speaking, for example, a small or medium-sized enterprise needs a diesel generator with a capacity of 30 to 60 kW to meet the normal business needs of the enterprise. However, when determining the ideal diesel generator for your business, it is important that the power be as accurate as possible. Today, ITCPower outlines how to estimate the best generator for you based on your power needs. In addition, you may find that ITCPower’s diesel generators are best suited for your business.
Why Diesel Generator Power is Important
There are many factors to consider when choosing backup power equipment, from the source of generator fuel to its brand to its noise reduction function. However, the power of the diesel generator may be the most important factor. If the generator has more power than you need, you may pay a lot more for the unit than you should have, and the operating costs of a larger diesel generator are higher.
On the other hand, if you choose a diesel generator with too little power to meet your daily business needs, it is possible to overload the diesel generator. If a diesel generator is operated forcibly to provide power beyond its capacity, the diesel generator will automatically shut off or may overheat, causing the diesel generator to overheat and damage the generator’s engine, as well as other electrical appliances using the generator’s power supply, and in some cases, diesel generator overload may also cause serious problems such as fires.
And even if you avoid overloading your diesel generator, choosing a diesel generator that is too small for your business needs means choosing which equipment to power during a power outage and having to give up power to some other equipment, such as running a production line or machine tool. To avoid this, you should consider in advance the maximum and minimum power capacity your business needs during power outages in order to get the best performance from diesel generators.
So, when choosing a diesel generator, the most important step is to calculate all the power needs of the enterprise
When calculating all the power needs of your business, first list all the equipment or appliances you want to supply during a power outage. You may need to list three types: electrical appliances (e.g. heating or air-conditioning systems) that need to be operated during power outages, office equipment (e.g. computers, printers, lighting systems, etc.) that need to be operated during power outages, manufacturing equipment (e.g. production lines, machine tools, cranes, etc.), and equipment or electrical appliances that do not need to be operated. This allows you to determine the approximate power level and operating cost for each level and make the best choice based on your budget expectations.
Supply power to all or part of the facility
Although some companies only want one that will allow them to run selected units during a power outage, more companies prefer a diesel generator that will power all of them at the same time. Large diesel generators allow your business to operate as if it never had a power outage. As a result, they provide more consistent and reliable power.
The diesel generator set is nominal in our country with the common power, i.e. continuous power. The maximum power that the generator set can use continuously within 24 hours is called continuous power. In a certain period of time, the standard is that within 12 hours, one hour can overload 10% on the basis of continuous power. At this time, the unit power is what we usually call maximum power, i.e. standby power. If you buy a main 40Okw unit, you can run to 440kw in one hour within 12 hours, if you buy a spare 400KW unit, if you do not overload the unit normally at 400kw, in fact, the unit has been operating at overload state (because the actual rated power of the unit is only 360KW), which is very unfavorable to the unit, will shorten the life of the unit and increase the failure rate.
Generally, the power of diesel generator units is clearly marked on the unit nameplate, but the nominal output power of each manufacturer is different, which is divided into standby power, prime power and continuous power.
- Standby power: It is defined as the maximum power that a generator unit can run continuously for 300 hours, up to 500 working hours per year, between specified service cycles and under specified environmental conditions. It is equivalent to time-limited operating power (LTP) in national standard and ISO standard. Generally, it is suitable for accidental emergency conditions with more load changes such as communication, building, etc.
- Common power: defined as the maximum power that exists in a variable power sequence with unrestricted number of hours of possible operation per year between specified service cycles and under specified environmental conditions, equal to the basic power (PRP) in the national standard and ISO standard. Generally, it is applicable to the normal operating conditions with less load changes in factories, mines and military.
- Continuous power: defined as the maximum power that exists in a constant power sequence with unrestricted possible operating time per year between specified service cycles and under specified environmental conditions. Equivalent to continuous power (COP) in national standard and ISO standard. Generally, it is suitable for continuous operation conditions with minimal load change, such as power station or grid connection with municipal power.
So why do you usually use the full power of the usual power of a diesel generator when using a generator, and what happens to an “under-load” diesel generator?
At ITCPower, we offer customized power solutions for diesel generators to ensure you get the exact power you need from diesel generators. When deciding which diesel generator set is right for you, we provide a number of guidelines to help you select the generator that suits your needs. In this article, we will show you the disadvantages of running the generator under load and help you understand why you need a generator with the correct kVa to meet your needs.
What is “Underload”
Underload of diesel generators is the practice of running generators with a load that is lighter than the design load. The “load” of a diesel generator is the power that the generator consumes. The ideal load of the generator is in kVa. For advice on finding the ideal generator kVa for you, please contact the ITCPower team of experts immediately.
Why shouldn’t we owe it?
Underload can cause serious damage to the diesel generator and, if left uncontrolled, slight wear can accumulate rapidly. When the load is insufficient, the diesel generator must work harder to reach its operating temperature. This not only tightens the plug, but also the diesel engine. Insufficient load can cause low cylinder pressure, making it more difficult for your diesel generator set to work to maintain efficiency, and causing accumulated soot to quickly block the cylinders. Together, these problems can quickly shut down your generator.
By far the most serious and terrible common problem that diesel generators may cause by running under-load is vitrification. Glassing occurs when the generator cannot reach the operating temperature due to under-load. The unburned fuel produces a thick syrupy substance that slowly clogs the piston rings. Blockage can destroy the seal formed by the piston ring, allowing combustion-generated exhaust gas to slide through the piston ring of the generator. Hot gas flashes the baking substance to form a hard ceramic coating that will quickly destroy your diesel generator.
How to avoid under-load
The easiest way to avoid under-loading is to make sure that the generator you buy has the correct kVa. If you already have a generator and are running under load, try to get your generator running at 70-100% speed. This is the best choice for most diesel generators. You may need a load box to help you get there. In addition, frequent maintenance, maintenance and testing can help mitigate the effects of under-load.
Of course, with the help of an expert team, you can rest assured that you have chosen the diesel generator that best suits your needs. All our customized power solutions are designed to ensure that they operate under loads that meet your generator needs.