How to Improve Industrial Generator Fuel Efficiency

As a business owner, you must worry about the everyday operating costs for your company. One way you can reduce costs is by keeping your industrial generator efficient year-round. A poorly maintained generator will burn fuel faster and strain the engine, potentially leading to additional repairs and a shortened generator lifespan.

Taking a few proactive steps today can help you reduce fuel costs, maximize efficiency, and extend the life of your industrial power system.

Conduct Regular Load Testing

It’s essential to load your generator at regular intervals to boost overall fuel efficiency. Remember to stay around 75% of the unit’s rated capacity—not too low or too high. If the generator continually operates at low loads, the unburned fuel and soot will start accumulating inside the engine, which is known as “wet stacking.” Wet stacking forces your engine to work harder and use more fuel than it should. If left unaddressed, it can lead to overheating and extreme damage to engine parts and components. Load banking will allow you to burn off excess carbon buildup to maintain efficient generator operation. Exceeding the generator’s capacity can also cause damage, so it’s essential to act with care when it comes to load testing. If needed, you can rely on our team at Valley Power Systems to handle the job. industrial generator fuel efficiency

Regularly testing your generator can also help you identify obvious problems with the unit. For example, you might notice strange sounds, such as excessive vibrations, grinding, or rattling. These can indicate damaged or misaligned components, which can also negatively impact efficiency. Testing will also give you an opportunity to inspect the system for leaks. Leaks put additional strain on the engine, reducing efficiency and potentially leading to further problems. If you note any fuel, oil, or coolant leaks pooling under or next to your system, contact our professionals immediately for service.

Upgrade Older Parts and Components

You don’t always need a complete generator replacement to maintain efficiency. Your existing system may just need some upgrades to enhance its performance, especially if it still has years of useful service ahead. Many components can be replaced as they wear, such as fuel injectors, filters, turbo components, sensors, and cooling system parts. New parts can offer better efficiency, using less fuel and extending the lifespan of your system. If you suspect some parts or components need an upgrade, contact our team at Valley Power Systems. We can conduct a complete assessment of the condition of your generator and provide cost-effective recommendations for restoring its efficiency.

Take Advantage of Remote Monitoring

If you don’t have a remote monitoring system, you’re missing out on key benefits. These advanced systems can track fuel use and alert you to various performance issues early on. By addressing repairs promptly, you can increase the overall efficiency of your system and prevent costly problems later. Best of all, you can manage your remote monitoring system from anywhere via a smart device.

Ensure Proper Ventilation and Cooling

Overheating is a common cause of generator failure. A hot engine will burn more fuel, increasing your costs while reducing generator performance. Overheating can lead to extreme engine damage, sometimes beyond repair. It’s crucial to keep your generator properly ventilated and cooled. You should inspect the area regularly for trash and debris that could block generator vents. Additionally, ensure that the system’s coolant is always within the recommended level. These steps will go a long way toward improving airflow and keeping the engine cool, which in turn enhances efficiency.

Change Air Filters

Clean air filters are necessary for blocking dirt, dust, debris, and other particulates. When filters become clogged, they restrict airflow and make the engine work harder than necessary. This will eventually reduce efficiency and cause performance problems for your generator. Air filters should be checked in between maintenance visits to maintain cleanliness. Additionally, we recommend inspecting your filters after major weather events, such as high winds or snowstorms, as these can stir up extra debris in the air.

Schedule Routine Maintenance

Many problems with your generator can be avoided with preventative maintenance. Regular generator maintenance helps keep your system clean and efficient and provides early detection of costly generator issues. Valley Power Systems is proud to offer customized maintenance plans. Whether you have an older power system or a brand-new generator, our team can personalize your plan to fit your unit’s needs now and in the future. Our goal is to ensure your generator receives the timely services it requires to stay up and running throughout the year.

Our maintenance technicians handle a wide range of tasks during your appointment. We cover oil and filter changes, leak inspections, battery checks, cooling system inspection, performance testing, and much more. Our technicians are highly experienced and certified to address any issues with your natural gas or diesel power system. During maintenance, we ensure all necessary tasks are completed, and we also look for common signs of wear on generator parts and components. If we notice any issues with your system, we’ll provide you with the best repair options for enhancing the reliability, safety, and efficiency of your system.

Key Consideration: Is Your Generator the Right Size?

If your generator has been progressively consuming more fuel over the years, it could be a sign that it is no longer efficient for your power needs. As your business grows, so does your power demand. It’s important to have an industrial generator that can keep up. Using a too-small generator will increase fuel consumption and cause excessive wear. However, an overpowered generator will waste fuel trying to maintain output you don’t actually need, leading to wet stacking and performance issues. To ensure you’re using the right size generator, contact our team at Valley Power Systems. We’ll calculate your power requirements and provide an accurate recommendation to maintain efficiency at your site.

Valley Power Systems: Your Power Partner

Need maintenance for your diesel or natural gas generator? You can rely on our expert technicians at Valley Power Systems for the job. We also handle generator repairs, installation, and sales. We’ve been serving California businesses since 1949, so you can trust that we’ll be here for any of your generator needs over the years.

We’re proud to be an authorized distributor for top names like Atlas Copco, Blue Star Power Systems, and Waukesha. You can count on us to offer the latest power solutions and reliable services from highly qualified technicians.

Fuel is one of the biggest ongoing costs associated with industrial generators, but our tips can help you save while protecting your power equipment. Contact Valley Power Systems today to learn more!