Rental - Power Rental - Spring 2015

POWER RENTAL Find the latest news at ForConstructionPros.com/RENTAL

Spring 2015

4

New Generators for Your Inventory

A supplement to Rental magazine

14

Questions to Ask Your Customers

Before They Rent a Generator

10 HOW TO HELP GENERATE

CLEAN POWER ON THE JOBSITE

6 Does the Mobile Power Market Have a

BIG ENOUGH ENGINE to Drive Your Business?

AWARD-WINNING

MOBILE GENERATORS FROM KOHLER POWER SYSTEMS, PAGE 20

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Serious power

starts here

ations c i l p p la For al Night and d

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Built for extreme environments and most demanding applications At Wacker Neuson, we’ve leveraged more than 160 years of construction and industrial experience into the design of equipment that’s built to endure the most extreme environments, the most demanding applications, the highest requirements for safety and durability. And we back it all up with an experienced, certified service team that’s dedicated to keeping your equipment running at peak so you can stay on schedule and on budget.

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POWER RENTAL SPRING 2014

FROM THE EDITOR B y J e n ny L e s c o h i e r, e d i t o r

It’s Not All About Oil

A supplement to Rental magazine

DOES THE MOBILE POWER MARKET HAVE A BIG ENOUGH ENGINE TO DRIVE YOUR BUSINESS? Market Overview Mobile power looks a bit flat this year, but demand from key markets promises to provide the gas for future expansion in years to come.

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4 NEW PRODUCTS

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HOW TO HELP GENERATE CLEAN JOBSITE POWER On the Job Protect your generators and the equipment they power by understanding the need for consistent voltage and how to ensure it.

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THE IMPORTANCE OF TESTING GENERATORS Fleet Maintenance Know which tests and inspections are needed to keep your machines in compliance and safe and effective for your customers.

QUESTIONS TO ASK YOUR CUSTOMERS BEFORE THEY RENT A GENERATOR

Declining oil prices have had a dampening effect on the market for mobile power, but there’s enough demand from other segments to support growth in the years to come

A

sk anyone in the mobile power business about the forces affecting their markets today and the discussion inevitably turns to oil and gas prices. The cost of this commodity is causing a ripple effect being felt one way or another by many businesses.

It’s true that steadily dropping oil prices have reduced demand for mobile power equipment in the US exploration for oil. The good news, however, is that production remains strong and continues to create a need for mobile power. And lower oil prices mean less money is spent on fuel, which translates into more money in everyone’s pockets.

Also positive is the fact that lower prices are putting a greater emphasis on the need to drive down costs on well sites. As a result, gaseous generators are being introduced that run off of well gas, providing significant cost savings over diesel generators.

The adaption of these machines is just beginning but is growing steadily, according to our sources. It’s great to see product innovations that not only save businesses money, but are also promoting a sustainable means of powering equipment. Now that this equipment is available, the challenge is in getting customers to understand and buy into the benefits of using it. We can all play a role in that.

So yes, the market for mobile power has flattened out a bit since last year, but solid growth is expected in 2016-17. All the economic indicators that drive the rental business are predicted to be healthy, so demand promises to be strong going forward, and there’s nothing wrong with that. ■

Management Perspective Understanding a little bit about electricity will help you comprehend the parameters of your customer’s job and ensure you provide the right generator for his or her needs.

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

NEW PRODUCTS Å Cummins DPF-Free Tier 4 Final Mobile Generators

The C150D2R and C200D2R Tier 4 Final-certified generator sets are rated at 150and 200-kW standby power, respectively.

• Permanent magnet generator (PMG) • Rugged four-cycle industrial diesel engines with a DPF-free design • Paralleling, dual frequency and four-point voltage selections • Standard integral set-mounted radiator system • Two-stage spin-on fuel filter w/pre-filter water separator with drain Search: 11364008

Æ Doosan NG160, NG225 and NG295 Natural Gas Generators

The NG160, NG225 and NG295 natural gas-powered generators combine the ability to operate on wellhead natural gas with rugged, reliable features that ensure performance in remote locations and harsh environments.

• Automatic dual-fuel switch allows operation on propane as well as natural gas • Onboard Scrubber System improves performance by removing excess dirt and water from wellhead gas • Operators can select 50 or 60 Hz with the flip of a switch and choose between 480V or 600V alternator output • Diagnostics and uptime supported by a standard telematics system (advanced satellite options available) • Other features include a rugged running gear, galvannealed enclosure and at-a-glance control panel monitoring Search: 12002490

Æ HiPower

Sytems Natural Gas Generators

Ç Chicago Pneumatic

CPG 25 and CPG 45 T4F The Chicago Pneumatic CPG 25 and CPG 45 T4F mobile prime power diesel generators are ideal for heavy-duty applications found on demanding construction sites.

• Environmentally sensitive, offering the flexibility to match the machine to a wide range of applications

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HiPower Systems works with leading engine companies such as Power Solutions International and relies on its PSI-GM Vortec Series and PSI Heavy Duty Series to provide reliable natural gas generator operation.

• Sound-attenuated, totally enclosed and bounded portable models available in a variety of sizes • Heavy-duty two-stage air filters and three-way catalytic converters designed to meet current EPA emission standards • Deep Sea Electronics advanced digital controller with remote access, optional load sharing and telematics

• Built for rental applications

• Crankcase ventilation filter with thermal insulation system provides optimal oil coalescence pressure control

• Compact, sound-attenuated, corrosion-resistant enclosure, which offers a single lift point and 110 percent fluid containment

• Stainless-steel enclosures specifically engineered for hotterburning, spark ignited, internal combustion natural gas engines

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SPRING 2015

POWER RENTAL

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POWER RENTAL Æ Honda Model EB10000

Industrial Series Generator

Ç Wacker Neuson G 625 Mobile Generator

Available in skid or trailer mount, the G 625 is powered by a rugged Volvo Tier 2 engine housed in a heavy-duty soundattenuated enclosure suited for jobsites requiring quiet operation.

• Produces 500-kW (625 kVA) prime power and 550-kW (688 kVA) standby power • Digital controller monitors and protects the generator and engine while providing continuous operating data via an LCD display

The rugged EB10000 generator is compact, lightweight and features a narrow-shaped design, centralized exhaust mechanism and newly developed alternator.

• Provides a maximum output of 10,000 watts • Digital Auto Voltage Regulator (DAVR) improves output capability by holding the voltage stable within 1% over time during standard operation • i-Monitor digital operation system with lighting for at a glance condition monitoring • Frame design clearly delineates hot and cool operating parts • Operates at approximately 72 dB at 23 ft.

• Powered by a Honda GX630 V-Twin engine Search: 12054466

• Deep Sea 8610 controller and motorized circuit breaker allow paralleling operation

WANT MORE PRODUCT INFO?

• Includes 110% fluid containment with liquid level alarm, fuel level gauge at fill point and no-mess oil and radiator designs

USE THE EIGHT-DIGIT CODE

• Standard battery disconnect switch, circulation coolant heater, engine oil drain with manual pump, low coolant shutdown, dual-stage Racor fuel filter with water separation and battery charger Search: 12054420

Æ Subaru

Upgraded SGX Generators The SGX3500, SGX5000 and SGX7500E generators have been upgraded with larger fuel tanks, no-flat tires, larger mufflers and a new blue and silver look to coordinate with the company’s automotive division.

• Feature 7- to 14-hp Subaru EX Series overhead cam engines with engine on/ off switch mounted on the control panel • Upgraded hour meter displays total operating hours even when the unit is not running • Low-tone mufflers nearly double the size of previous models

For more information on any of the products in this issue, simply type the unique eight-digit code into the search bar at the top of www.ForConstructionPros.com/Rental.

Å Atlas Copco QAS 25

and QAS 45 Generators The QAS 25 and QAS 45 generators are now powered by 32.5- and 59-hp Isuzu diesel engines for diesel oxidation catalystonly Tier 4 Final emissions compliance.

• Oxidation catalyst offers flow-through exhaust aftertreatment requiring no regeneration, maintenance or periodic replacement • Feature the same package for commonality in controls to reduce operator training and parts commonality to reduce inventory • QAS 25 offers 45 hours of runtime at 75% load and the QAS 45 provides 30 hours of runtime at 75% load on a single fill-up • Basic maintenance intervals extended to 500 hours • Heavy-duty, single-axle trailer Search: 12048947

Å Kohler 145REOZT4

and 175REOZT4 Diesel Generators The 145REOZT4 and 175REOZT4 diesel mobile generators achieve high power density, high torque and low fuel consumption with John Deere 6.8L Tier 4 Final diesel engines.

• 145REOZT4 offers a 130-kW standby rating, and the 175REOZT4 generator achieves a 154-kW standby rating • Parallel-capable system with 4.3-in. backlit color LCD display • Remote-start and remote-stop convenience • Heavy-duty air cleaner with restriction indicator • Fuel tanks sized for 24-hour runtime

• Wheel kits with two no-flat tires offer enhanced portability

• 110% environmental containment for fuel, oil and coolant

• 4- to 8-gal. fuel tank sizes

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MARKET OVERVIEW

POWER RENTAL

B y J e n ny L e s c o h i e r, e d i t o r

Does the Mobile Power Market Have a

BIG ENOUGH ENGINE to Drive Your Business?

Mobile power looks a bit flat this year, but demand from key markets promises to provide the gas for future expansion in years to come

T

he market for mobile power can involve some neckbreaking swings of the pendulum, depending on numerous economic factors. Today, the adoption of Tier 4 Final engines and anxiety over the oil and gas market are main factors in the demand for generators. To get a feel for what’s happening, we asked several industry stakeholders what they’re seeing.

Following is an excerpt from that discussion: Rental: How would you characterize the current market for mobile power?

Emily Kocik, marketing & strategy manager - global rental segment, Cummins Power Generation: The

rental market has seen consistent growth, especially for temporary power.

We’ve seen an increase in business over the last 3-5 years in North America and in other parts of the world across

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our entire product range, especially for containerized sets. [End-users] are looking for rental power suppliers who can respond quickly and provide equipment that is fuel efficient, highly reliable and meets all current environmental requirements.

Todd Howe, product marketing manager - generators, Doosan Portable Power: Business is good, utilization is high, there are definitely good conditions out there. It’s not necessarily lining up with investment or expansion in fleet, but that’s got more to do with things like Tier 4 as opposed to the general health of the construction industry and other markets the rental industry serves. I see things going in a positive direction but at a much slower pace than last year. Rental companies are trying to get rental rates on Tier 4 products to come up so they can get good ROI on a much more expensive asset.

That’s really the challenge we’re facing. I think it’s going to take us another couple of years to get Tier 4 acceptance fully ingrained in the end user from both an understanding of what the costs are as well as the operating implications when using a product that’s got a Tier 4 engine in it.

Terry Dolan, executive vice president, Generac Mobile Products: There are challenges in the mobile power market, but it is growing. We are cautiously optimistic about the prospects for the year. The general health of the economy will drive the need for mobile power equipment. There is a definite need for mobile power in the marketplace, and it continues to adapt to new Tier 4 products. The current demand for higher-tier diesel products is a bit soft, though. Customers prefer Tier 3 flex generators, as these models are less expensive and don’t require additional

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emission management items.

The recent drop in oil prices has impacted oil and gas production, which has put higher visibility on the need to drive production costs down on well sites. The emergence of gaseous generators that run off of well gas provides great cost savings compared with diesel generators. The adaption of this innovative product has been increasing over the past year. We also are experiencing increased activity in other industries, such as construction and hospitality.

The fluctuating oil and gas prices, harsh Northeast winter and engine tier transition have resulted in lower demand in 2015 compared with 2014.

We do expect demand to increase as we see stabilization in the market. An uptick in the housing market will combine with increased use of mobile power during summer construction to drive demand.

Tony Crandall, Buckeye Power Sales, Columbus, OH: Here in the Midwest we’re starting to see a resurgence in industrial work as last year industrial work decreased significantly. Now we are also starting to get a lot of requests for medium- to large-scale event work, which is a welcome expansion for us.

Anne Feudner, product manager, Kohler Co.: This year, were projecting a pretty strong double-digit growth.

By 2019, were expecting things to slow down to just north of GDP. Rental: How much of a factor is the oil and gas segment in the current demand for mobile power?

Dolan: The oil and gas segment is a major factor in the demand for mobile power. Demand has been very strong in past years, but recently, lower oil prices have reduced rates and utilization of mobile power in the oil and gas segment. This has resulted in a lower demand for new products and a reallocation of existing units from the oil and gas market to markets with stronger demand, such as construction.

There are big opportunities for gaseous generators because of their improved

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economics and the desire of end users to reduce their consumable fuel costs. This is a significant factor in the demand for mobile power, and we believe it will continue to be one in the long term.

Feudner: Oil and gas exploration is slowing, but is more than offset by the rent vs. buy value proposition. From a manufacturer’s perspective, we believe the market is still growing based on rental vs. buy economics and strong growth in nonresidential construction.

We have a broader base of customers, so we can ride it out. The slowdown in oil and gas will hurt service providers which serve strictly that industry. In the end, we believe the industry is slowing down but it will come back.

Howe: Our product is used predominantly in oil and gas production to establish well sites, actively get the oil out of the wells. The headlines we’re seeing lately have more to do with the drilling side - companies laying off thousands of people, idle drill counts.

The reality is that the production side is still very strong. Our natural gas generator lines play very well into that because in difficult times, even production sites are looking to cut costs where they can.

Natural gas generators that can run on well head gas that would otherwise be wasted offer a huge operating expense

many different applications without a lot of reconfiguration or special requirements. The G25 is a great machine for construction jobsite applications; small but very portable on the jobsite. The G70 is for the same types of jobs but on a larger scale. From there, it varies all over the place, depending on particular market requirements.

Kocik: There appears to be a growing demand for alternative fuel and non-diesel powered generators, especially in the oil and gas segment. We’ve also seen a growing demand for containerized rental generator sets above 1000kW. Andrea Stone, Kinsley Power Systes, East Granby, CT: We’re seeing demand for 100kWs, which are small and easily portable, and also 1mg units that can back up an entire building. There’s been a shift certainly in the Northeast after all the major weather events of the past couple of years.

Businesses and buildings are doing full-scale building and facility backup instead of just life safety backup. It’s really shifted the size requirements that people are looking for in generators.

Crandall: That’s pretty prevalent here too. If there’s going to a be a long-term outage expected - anything longer than 1-2 days - customers will actually bring in larger units to power

“There’s a growing demand for

alternative fuel and non-diesel powered generators.” decrease versus having to pay for diesel fuel delivery to a remote well site.

Rental: What type of machines and ser vices are in the greatest demand? By whom?

Howe: Most rental companies have a couple of Swiss army knives in their tool kit and it’s the G25 and the G70 class. Those are very popular fleet machines and can be deployed across

their entire facility, even though they already have a small, permanently installed generator on site. The smaller machines traditionally are only capable of powering the critical loads and won’t necessarily allow the customer to continue operating at full capacity.

Dolan: Demands for machines and services vary across sectors. The construction market necessitates smaller, POWER RENTAL

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MARKET OVERVIEW more compact, reliable units, while the oil and gas market requires additional products and services because of the need for consistent power 24 hours a day, 365 days a year. The machines that the oil and gas segment requires are diesel and gaseous generators, light towers, heaters and pumps.

We have seen strong interest in gaseous-fueled mobile power generators.

Oil and gas production companies have shown an interest in reducing the amount of flaring done in the field, and gaseous-fueled generators economically maximize field gas that would otherwise be flared off.

Rental: What can equipment rental businesses do to best serve the need for mobile power?

Stone: We have an emergency response team which is comprised of our rental department and our service department. We start notifying key customers days in advance of expected weather events and tell them what’s happening and ask them what they want and where they want it. We try to be as fully deployed as possible ahead of the weather. You need to be rental ready all the time.

Crandall: Not only do you need to have the fleet but you need the fleet to be fully ready to go via a quality maintenance program. Servicing of the fleet is a major priority for all rental companies. During emergencies, you’re pretty much guaranteed the machine is going to be deployed quickly and running 24/7. In the industrial world, most of the time a machine is either in a standby application or running 6-10 hours a day on average, if it is not a full planned outage. You really need to have a good service team in place to ensure all equipment is “rent ready.”

Kocik: Rental businesses can serve this growing demand by offering a complete range of EPA MOH certified products for diesel, natural gas, propane and nonstandard gas for oil field flare gas. To meet larger power demands, rental businesses can integrate their fleets with units that are capable of simple

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paralleling and varying load functionalities. Rental businesses can also serve the growing demand for containerized units by offering complete, turn-key power solutions from pre to post sale.

Dolan: Rental businesses need to offer a breadth of products and rapid 24/7 response service to meet the evolving demands of the mobile power market. They need products to be available on short notice and for these products to be configured to fit the customer’s application.

Rental businesses also should make sure team members are trained in sales and technical service so they can fully support their customers. For example, many oil and gas production companies are still not aware of the advantages of new gaseous-fueled mobile power generators. This is an area where equipment rental companies can help educate their customers.

new products that offer more reliability and are easier to service with longer intervals between preventive maintenance. This can save rental companies thousands of dollars in maintenance over the life of the product. These new products help the rental company with utilization and lowering operating costs, which helps profitability for both the rental company and end user.

In addition, there will be a focus on providing larger power nodes through paralleling multiple units. Customers also are seeking more turnkey solutions to various issues, including power distribution and site set up.

Finally, we see the interest in gaseous generators continuing to grow. They make economic sense and are more environmentally friendly due to the more favorable emissions profile of natural gas versus other fuel types. It’s a win-win-win for equipment providers, rental compa-

“Fluctuating oil and gas prices and engine tier transition has resulted in

lower demand in 2015.”

Howe: You really need to understand what the customer is doing with the product and what their application is in order to give them the best possible solution. You want to make sure you’re sizing your customer’s need to the right piece of equipment, particularly in the Tier 4 world. If you give a customer a 100 kW generator and he only needs a 20 kW, you’re not providing him value because you’re overcharging him for a much larger machine than he needs, and you’re dramatically underloading your 100 kW machine, which is going to cost you down the road in the form of extra maintenance.

Rental: Where do you see the market headed in the coming year or two?

Dolan: Specific end markets will see

nies and production companies.

Howe: I think it’s going to be healthy. The rental industry came out of its normal cycle as companies tried to get a hold of as much pre-Tier 4 product as they could. That changed the normal buying behavior of the big nationals which are the companies that really drive the shape of the curves that affect this industry. That said, this year is probably pretty flat but next year and 2017 we’re predicting to be up. All the macro indicators that would drive rental business are going to be healthy. There’s infrastructure spending going on, as well as commercial and residential building. All things point to continued investment, which points to continued need for rental equipment and expanded power. ■

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Search: 10073928

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ON THE JOB

by Cur t Bennink, contributing editor

How to Help Generate Clean Jobsite Power Protect your generators and the equipment they power by understanding the need for consistent voltage and how to ensure it

Instruct customers to keep the continuous power rating in mind when operating your generators. Exceeding this for too long could cause damage.

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he quality of electricity generated varies between generators. Clean power is electricity that maintains a consistent voltage while producing a steady 60-Hz frequency with no harmonics.

To achieve clean power, one of the most important considerations is the generator’s continuous power rating, which is the maximum amount of power that a generator can run at for an indefinite period of time without degradation or damage. The standby rating represents the maximum amount of power the generator can produce for short periods of time without overheating or causing damage. It’s important to note that extended use at the standby

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rating output can cause damage and reduce the useful life of the generator.

Generator rating terminology differs between small portable models and towable units. “Typically, in smaller generator models (less than 10,000 watts), the model number reflects a maximum power rating,” says Rick Bernier, national product specialist, sales application engineering, Wacker Neuson. “This is the temporary amount of power a generator can deliver for about 30 minutes in a six-hour period.”

Beyond that time frame, the generator must be run at a lighter load or be turned off for six hours to allow it to cool down before it can carry this load size again. “It is recommended you choose a generator that is at least

10 percent larger than your continuous power needs, so you have extra capacity for unexpected load requirements,” Bernier advises.

Towables have a slightly different nomenclature. “Typically, a towable unit is rated in prime power, then it has a 10-percent overload rating that will get it to what is called the standby rating,” notes Todd Howe with Doosan Portable Power. “This is the maximum amount of power you can pull out of the generator. If you operate it there, you would have a reduced lifespan.”

Units used in emergency applications are typically sized according to the standby rating, because they are not going to run very much and therefore will have a useful service life. “A mobile

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application for rental and construction, keeping it at the prime power rating, will ensure the unit will live to maybe a 10,000-hour lifespan,” says Howe.

Do the math The math to determine the required size for a single-phase generator is rather straightforward.

As an example, Bernier cites a generator that must supply combined 120- and 240-volt loads. Assume that three 120-volt loads have amp draws of 2, 3 and 5 amps, or a total of 10 amps.

Multiply the voltage times the total amps to determine the wattage. In this case, it would be 120 volts x 10 amps = 1,200 watts. Let’s assume there is also one 240-volt load that draws 10 amps, or 240 volts x 10 amps = 2,400 watts.

Combined, the total power demand on the generator is 3,600 watts (1,200

+ 2,400). Consequently, you would need a generator that can supply both 120/240 volts and has a continuous rating of 3,600 watts or greater.

Now let’s look at the surge rating.

“The surge rating refers to the instantaneous amperage draw of a motor on first starting.

“This is the amount of power a generator can supply for about two seconds to start motors,” Bernier adds. “If all motors will start at the same time, add starting amps together and multiply by voltage to get total motor starting (surge) power. When in doubt about the sequence of motor starting, size for all motors starting at the same time.

“If motors will always start sequentially from largest to smallest, determine the worst case power surge,” he continues. “Is the largest motor the largest power surge, or does the power surge of

the last motor starting plus the running power of other motors total up to be the largest power surge? Choose a generator that is surge rated to or greater than your calculation. It must also be rated for the continuous run power you determined.”

According to Bernier, certain rules of thumb can be used to determine surge power in single-phase systems.

For example, if the motor label does not show starting amps, then calculate that brushed motors 1 to 5 hp in size typically require two times the running power to start. So a 1-hp motor that draws 1,200 watts would require surge power of 2,400 watts.

Clean power protects equipment To provide clean power, a generator must provide consistent power output with low voltage fluctuation. Consistent

POWER WITH

PERFORMANCE

Need a heavy-duty generator for demanding applications? Chicago Pneumatic has it. CP’s mobile generators offer extreme durability, intuitive controls and large fuel tanks for longer run time. Convenient maintenance access and longer service intervals also keep your operating costs down. From construction to public works to temporary power, count on CP generators. Learn more at cp.com

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ON THE JOB

Don’t forget about the tools too. Well-regulated voltage is the key to power tool durability and life.

voltage is necessary to ensure the operating loads do not draw more current than they are rated for.

“The better the voltage regulation, or the lower the percentage of variance, the better,” Howe says. “The application and type of equipment to be powered really determine how sensitive the voltage and frequency regulation needs to be.”

Some equipment is more sensitive to voltage fluctuations. Well-regulated voltage is the key to power tool durability and life. Wide variations in voltage can lead to over-speed, and high current conditions can lead to tool damage.

“The correct voltage extends the life of tools and appliances by allowing them to operate at designed temperature levels,” says Bernier. “Many of today’s tools contain protective power modules that will not allow the tool to operate if the voltage or frequency from a power source is outside of its design limits.”

On quality generators, voltage

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output is controlled through an electronic regulator. “The electronic voltage regulator monitors the voltage output to loads, much like a thermostat monitors the temperature in your house,” says Bernier. “The difference is the voltage regulator is lightning fast and responds to load changes in 1/100ths of a second. The faster the generator responds to load changes, the more stable, clean and equipment friendly the sinusoidal voltage output.”

Some low-cost portable generators don’t use voltage regulators. “Voltage control is more relaxed and comes from a rectifier or capacitor,” says Bernier.

“Motor starting surge is 1.5 to 1.7 times the run rating (vs. 2 to 2.5 for a premium model) and voltage output is not clean.

“The design of generator components contributes to clean voltage output by reducing harmonics,” he points out.

“Harmonics are additional unnecessary voltage sine waves sometimes referred

to as ‘noise.’ Harmonics can distort the primary sinusoidal voltage output.” To combat this, Wacker Neuson includes winding slots in its generator design that are skewed with a 2/3 pitch to reduce harmonics.

Consistent engine speed is critical Generators are designed to run at a certain speed. Maintaining this speed is critical to produce power at a consistent voltage and 60-Hz frequency.

“In mobile generator applications, where you have bigger units and more sophisticated control technology, we try to hold it to a half percent of voltage variation,” says Howe. “A quarter-percent frequency regulation is about the best you can do nowadays. The little portable gas- and diesel-powered machines still have mechanical governors and carburetor technology.

Typically, you are looking at +3% to -5%

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nominal speed on those.”

Larger generators with more extensive electronic controls will provide better power quality. “If you need precision power that closely approximates what we are used to getting from the utility grid, step up to a towable machine,” says Howe. “The portable machines are going to have way too much voltage and frequency variation.”

Single phase vs. three phase Both single-phase and three-phase generators are commonly found on jobsites. Single-phase generators contain the standard voltage that is delivered to most homes, either 120 or 240 volt.

They are adequate for running resistive loads, low power draw applications and machines with simple electric motors.

Three-phase generators are more efficient than single phase because the

resulting line currents are lower. Threephase generators are used for higher power applications where losses due to inefficiencies are significant. Threephase generators may be found running pumps, industrial motors, batch plants and other large scale electrically powered equipment.

Three-phase power delivers greater energy density. “A typical three-phase generator is like having three singlephase generators combined into one,” says Bernier. “Almost three full-voltage sine waves are produced in the same time period it takes for one sine wave to come from a single-phase generator. These sine waves overlap each other slightly and follow one another 120° apart. This allows three-phase motor manufacturers to install three windings in electric motors (5 hp and larger) to provide more power in a

smaller package.”

The differences between singlephase and three-phase generators are not visually apparent. “The difference basically has to do with the construction of the alternator,” says Howe. “A single-phase alternator has one set of windings that produce one sinusoidal AC sine wave of voltage. A three-phase alternator has three independent windings that each produce an independent sine wave.”

Larger generators, such as towables, typically offer three-phase power.

“Usually, when you are getting into three-phase power, you are looking at applications that have higher amperage requirements,” says Howe. “For example, you can get single-phase motors up to about 5 hp. Once you get 7 to 10 hp, you get single or three phase. Everything 15 hp and up is three phase.” ■

Portable

Generator Test Set Model 632 (15KW) | Model 627 (10KW) | Model 650 (30KW) Input voltage: 120/240V, 60Hz Single Phase

A self-contained test set for electrical load testing of AC generators. Ideal for setting engine speed and verifying engine and generator performance. Now you can be sure that your generators and alternators are providing the output they should, and the proper voltage frequency.

Generators up to 10-30KW can be loaded to full capacity. The generator test set combines two load banks in one. Larger generators can be tested using two test sets. This avoids purchasing a very large test set for only a small percentage of your generator inventory.

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MANAGEMENT PERSPECTIVE B y J e n ny L e s c o h i e r, e d i t o r

Questions to Ask Your Customers BEFORE They Rent a Generator Understanding a little bit about electricity will help you comprehend the parameters of your customer’s job and ensure you provide the right generator for his or her needs

R

enting your customer the right generator for his or her job is not as simple as pointing to the nearest model. You need to understand a little bit about electricity to adequately understand the parameters of your customer’s job and ensure you provide the right equipment for his or her needs.

According to Anne Feudner, product manager at Kohler Power Systems, the most important factors when choosing a generator are volts, amps and phase. By understanding the relationship between these three electrical values, you can help ensure your customer gets the right equipment for the job.

Volts vs. amps Voltage is a measure of the strength of an electrical current, Feudner says.

Household electrical current is 110 volts, while construction sites typically run on 208- or 480-volt current.

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Understanding volts, amps and phase will help you choose the right generator for your customer’s needs.

Amps, on the other hand, measure the volume of the electrical current.

“Think of electricity as though it were a bag of M&Ms,” she says. “There’s the small bag of M&Ms you get at the checkout line at the grocery store. That’s your 110-volt current. Then there’s the big bag of M&Ms you put in the candy dish at Christmas. That’s your 480-volt current. The number of M&Ms you take out of either bag is your amps.”

Another way of looking at it is this: Voltage is how much electricity there is, while amperage is how fast that electricity is moving (if at all).

Single- or three-phase Whether your customer needs a single- or three-phase generator depends on the size of the machinery they plan to run. Single-phase distribution is used when loads are mostly lighting and heating, with few large electric motors.

A single-phase supply connected to an alternating-current (AC) electric motor

does not produce a revolving magnetic field; single-phase motors need additional circuits for starting, and such motors are uncommon above 10 or 20 kW in rating.

High-power systems (hundreds of kVA or larger) are nearly always three phase. According to Craig Wilkens, business development manager, Doosan Portable Power, single-phase motors use one set of windings to start, while three-phase motors use three sets. “If you have a large motor to start, you need very large windings. With a threephase motor, you can make it smaller by connecting three sets of windings.”

Size is everything As you know, generators are available in a wide range of sizes. Generators with power supply capacities of 5kW to 50kW are readily available in the personal and home use markets, while industrial generators run anywhere from 50kW to over 3 Megawatts. Many

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people believe smaller generators can be used for standby electric power because they are not running all the time.

Unfortunately, generator under sizing is one of the most common mistakes when renting or buying a generator. Not only does it pose a potential risk to the generator, it can also damage other assets connected to it, create hazardous situations and limit overall productivity of the unit and/ or the business relying on it.

“If a generator is too small, it could fail catastrophically,” says Wilkens. At the very least, it will shut down, leaving your customer without power.

One way to avoid under sizing your generator is to be aware of the inrush current. Inrush current or

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“80 to 90 percent of generators on construction sites are oversized.” input surge current refers to the maximum, instantaneous input current drawn by an electrical device when first turned on. Pumps, for example, typically require high inrush current, Feudner says. Alternating current electric motors and transformers might draw several times their normal full-load current when first energized. For this reason, it’s important to factor in the anticipated inrush current when sizing a generator for a job. The amount of inrush current is affected by the number and type of tools being powered. Feudner says contractors can minimize inrush current by

Kohler Power Systems offers numerous products ideally suited to the rental market, including a full range of diesel and gaseous-fueled mobile generators.

These units offer customizable options for most applications and feature unmatched quality, reliability and flexibility. Built to withstand the elements and run long hours in prime and standby applications, Kohler’s mobile generators meet all emissions standards.

The company’s compact gaseous-fueled generators can easily switch between optional on-board LP fuel tanks and external LP liquid, LP gas or natural fuel sources. These models are also eligible for valuable incentives from the Propane Education & Research Council (PERC) and can help reduce fuel costs by an estimated 15 to 20 percent compared to diesel fuel.

A powerful and durable lineup of portable generators and pumps is also available from Kohler. The portable generators range from 2 to 12.3 kW and feature the company’s U-Spec™ accessory system, which allows for ultimate customization.

A range of accessories, including wheels,

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“sequencing” the electrical load by turning equipment on in stages.

Generators that are larger than necessary for the load won’t do immediate damage to equipment, but they can be detrimental in the long run by causing wet-stacking in the engine. More importantly, oversized generators are costly and wasteful.

“I would say 80 to 90 percent of generators on construction jobsites are oversized,” says Feudner. The reason is that naturally, contractors and rental sources want to err on the side of caution when sizing a generator to a

legs, extension cord management system, hand-trunk handle, and more can be easily added based on the end user’s specific requirements. The company’s water pumps – from 2 to 4 inches – can also be customized and are designed to stand up to the toughest jobs.

Kohler offers a number of support services to give rental companies an edge on the competition, including a premium three-year limited warranty and custom-engineered specials to design equipment that fits every job perfectly. The company’s global service and support network – with more than 800 locations worldwide – provides comprehensive aftermarket support to guarantee satisfaction.

Kohler Power Systems, a division of Kohler Co., provides complete power systems, including generators – portable, residential, industrial, and marine – automatic transfer switches, switchgear, monitoring controls, and accessories for emergency, prime power and energy-management applications.

The company has been delivering energy solutions worldwide since the 1920s.

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Ask a lot of questions. Find out from your customer exactly what they plan to do with your generator, what it will be powering and for how long.

load. By using a generator that’s too large, however, significant amounts of fuel are wasted, which adds to the cost of a project over time and has negative consequences to the environment.

Additional considerations There are several additional factors to think about when renting your customer a generator. “One important thing to consider is fuel capacity,” says Wilkens at Doosan. “How often will [they] need to refuel? Can a fuel truck come to the site or will [they] need an auxiliary day tank?”

Wilkens also suggests supplying generators with environmental containment systems. “To remediate a spill of diesel fuel on a 4- by 4-ft. piece of land costs $10,000. Contractors are required to ensure the equipment they use is environmentally compliant.”

Lastly, ask your customer if he or she needs any auxiliary equipment. Wilkens says this could include additional cable, extra distribution panels or an automatic transfer switch.

Be prepared to answer

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In order to provide the right equipment for your customer’s needs, you will need to get some important information.

According to Wilkens at Doosan, following are some questions to ask before supplying a generator: • What is the generator being used for?

• How many hours per day will the unit run?

• If long-term, who will perform 250-hr service and do they need fuel delivery? Do you need an additional external fuel tank and who will hook it up?

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• What voltage do you require?

208V, 240V, or 480V and singleor three-phase?

• If you need 208V and 480V, do you want two generators or one generator and a transformer?

• How many amps do you need?

Total amps (15 x 20 amp circuits = 300 total amps or 45 kVA) or amps per leg (300 amps 3 phase = 125 kVA) • If you want a transformer, what size (amps or kVA)?

• What kind of connections do you need?

Lugs, stud,

•

• • • • • •

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cam-lok or something more specific such as a certain NEMA configured pigtail?

Do you need primary feeder cable? If you need #1, 2/0 or 4/0, how many four- or five-wire sections do you need? (If someone says they need 200’ of feeder, they might actually mean 1,000’ of cable or 200’ x 3 hots, a neutral, and a ground.)

Do you need a PowerSource for standby generator?

If yes, would you like a transfer switch?

If yes, do you want manual or automatic?

Do you need distribution?

If yes, how many 20-amp 110V duplex circuits do you need?

How far apart do you desire the outlets to be?

On the toughest industrial job sites, you need a partner you can trust. To deliver rugged, reliable equipment, designed for extreme weather and potentially volatile conditions.

To focus on safety as the number one priority. And to be ready when you need service, with the expertise and the parts to get it right, right now. Because uptime is the only time that counts.

• Do you have a layout?

• Do you need any 220V outlets?

• If yes, where, how many, what a mp e r a g e , a n d w h at p lu g configuration?

• Do you need cable ramps? How many total feet?

• Do you need the equipment to be setup and taken down?

• Do you need a standby technician? From when to when?

The rental perspective Don Leher, industrial sales manager at Gen-Tech in Glendale, AZ, is in the business of helping customers choose the right generator for the job, and he says it comes down to getting as much information from that customer as possible.

“There are many scenarios in which a rental generator is required. In the

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At Wacker Neuson, we’ve spent more than 160 years working side by side with people who work where “extreme duty” has to be the standard. Our equipment has been proven tough and reliable on construction sites, in the oil fields of Alaska, the shale fields of the Bakken, Marcellus and Eagle Ford and in heavy industrial applications around the world.

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case of an event, for instance, the event organizer or the supplier of the equipment to be powered typically knows what the power demand is. They contact us, tell us what they want, and we provide the appropriate pieces of the puzzle to make it happen,” Leher says.

“The electrician on a jobsite might have a crisis because a utility transformer has failed and they need to power a building until normal power can be restored.

Often they will simply ask for a generator set capable of producing enough amps to match the ampacity of the service entrance section. They probably have no idea what the real load of the building is, and this is often considered the safest approach. After all, it is a temporary generator rather than a permanent installation, so if the generator is larger than needed, this is not a long-term problem.”

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Leher says they run into challenges when someone needs a generator set to start and run a large motor. This may be a pump system, or a building with a large number of small motors that can, and do, all start at the same time.

“In these instances we always try to determine the horsepower of the motors to be started, starting sequences if possible, and the method used to start the motor,” he says.

“A motor starting across the line can have a starting kilovolt amps demand that is six to 10 times the normal running amps, or it could be coupled to starting methods that minimize the starting demand. With this information we can normally provide a temporary generator to meet their needs without over sizing, and therefore over pricing, the unit.”

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information we can glean up front, the better match we can suggest for the project in terms of on-site power generation. There are really only three types of loads: resistive, motor and non linear. If we can gather enough information to help us determine the demand of each of the loads to be powered, we can calculate the requirements, ensure we have at least a 20% reserve capacity, and ensure the generator is properly sized.”

Unfortunately, many times temporary generators are sent to jobsites that are over sized because either the information was not available or no one asked the right questions. “In the rental generator business knowledge is king, just as it is in all business,” Leher says. “Knowing the right questions to ask, and asking them, is the best way to ensure the needs of the project are met.” ■

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FLEET MAINTENANCE B y M a r k S o tc h e r, p r e s i d e n t o f S o tc h e r M e a s u r e m e n t I n c .

POWER RENTAL

The Importance of Testing Generators Know which tests and inspections are needed to keep your machines in compliance, as well as safe and effective for your customers ne of the most important parts of successful power rentals is matching the generator to your customer’s needs.

A simple way to estimate the correct generator size is to consider the type of load the customer is applying. If it’s just lighting, then you can simply total up the wattage of the lamps to be operated, add a small safety factor and that is the generator size required. If the customer is applying a mixed load of hand tools, then a safety factor of two times the estimated load is appropriate. On the other hand, if the customer is planning to operate machines that will be fully loaded, then a safety factor of three times the rated wattage should be considered to allow for the start-up current required, as various machines are turned off and on.

Tests and inspections Upon returning from a rental, the generator should be visually inspected: • Are there any loose, damaged or missing parts?

• Are the safety labels in place and easy to read?

• Is the fuel tank full?

• Is the fuel tank valve shut off?

• Is the oil level up to the full mark?

• Are all safety guards in place?

Next the generator should be tested: • Perform a manual test of each ground fault circuit interrupter (GFCI).

• Apply a load equal to at least 2/3 the generator’s capacity.

• Verify that the output voltage and frequency is within specifications under no load and full load.

• Test the ground bonding from the receptacle’s ground pin to the frame of the generator.

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Why not just use a voltmeter? Sure you can do it that way, but it’s like trying to judge a car’s performance by racing the engine on the side of the road. If you want to provide your customers with quality products they can depend on, you need to inspect them, test them and document the results.

What are the rules?

Grounding refers to the connection of an electrical circuit or equipment to a reference ground, such as the generator’s frame or a ground rod. Bonding is the intentional connection between the neutral wire and the grounding means of the generator, which includes the frame of the generator. The term bonding is also used to describe the intentional electrical connection of components such as the gas tank or engine to the frame of the generator. Keep in mind OSHA has two specifications, one dealing with grounding the generator and the other with bonding the neutral to the frame.

In accordance with OSHA, portable generators used on construction sites do not need to be connected to a ground rod, provided the generator supplies only equipment connected through receptacles on the generator, and the equipment is grounding through the receptacles to the frame Note the generator’s noncurrentcarrying metal parts such as the fuel tank, the internal combustion engine and the generator’s housing must also be bonded to the frame.

Generators used on construction sites supplying cord-and-plug connected equipment (tools, lights, etc.) are considered a “separately derived system” in the National Electrical Code

and thus the neutral must be bonded to the frame of the generator.

Test for proper grounding or bonding For operator safety the grounding and bonding circuits must provide a low-resistance connection and must be capable of conducting a surge of electrical current.

Sotcher offers a Ground/Neutral Continuity Tester for portable generators. It tests the integrity of the ground and neutral connections from each of the receptacles to the frame of the generator. The test is conducted at a full 10 amperes of current and tests for a resistance of 0.2 ohms or less. A panel-mounted meter monitors the current flow. Adapters are offered to match all standard receptacles.

Why not just use an ohmmeter?

An ohmmeter will indicate if there is an electrical connection, but it cannot tell you if the connection is a single strand of wire or a solid connection.

Remember, you are depending on the bonding connection to conduct a surge of current if a short circuit should occur.

What is wet stacking?

Diesel-driven units are subject to particular malady known as “wet stacking” or “slobbering,” which stems from operation under no-load or light-load conditions. Such operations cause fuel deposits to collect on the combustion chamber, injector nozzles, piston rings, turbo-charger and exhaust system.

The result is diminished engine output capacity. Fully loading the generator for a time period will clear this condition.

Remember, the future of your company depends on the quality of the service you provide your customers. ■ POWER RENTAL

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