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If the power fails, the generator can be your only lifeline, so please consider your options to ensure that the generator in your data center meets your initial and future needs.

The International Organization for Standardization (ISO) categorizes generators in a variety of ways based on usage: emergency standby, which means that these generators can run up to 200 hours per year; Prime, run unlimited hours per year; and continuous rating. Emergency backup generators are the norm, but ISO stipulates that their use is reliable.

Caterpillar manufactures its entire power system, from engines and alternators to switchgear, fuel tanks and smaller generator set enclosures. Their alternator can only work when the engine is started and running reliably, but the engine they make runs on the same standard as the engine that runs heavy equipment. Their standby rated generators can operate during power outages and exceed the Tier certification requirements of the ISO Standby and Uptime Institute without the need for scale-up or other special treatment.

Caterpillar offers more than 80 generator models, including diesel and natural gas options in 50 and 60 Hz versions, as well as specific configurations for each country in the world. Mission-critical facilities often use 1.5 MW and larger 3500 and C175 series diesel backup generators, the most popular being 2 MW to 2.5 MW units. Caterpillar also offers devices up to 4 MW that meet all basic requirements. Pricing depends on the voltage, fuel, whether the generator is closed, and the details of the installation.

Cummins provides industrial diesel and natural gas backup generators and cogeneration products. They design, manufacture and sell their own engines, alternators, switchgear, fuel tanks, batteries, control devices and enclosures. They also produce hydrogen production and fuel cell products. Diesel remains the main choice for mission-critical installations, and the most popular size range is 1000-3000 kW. Cummins recommends installing mission-critical generators indoors or in effective external enclosures, combined with dual-start batteries, block heaters, and at least 12 hours of external fuel capacity.

For relatively basic mission-critical configurations in the 1000-3,000 kW range, Cummins recommends a budget of at least $350 per kilowatt, plus contractor's price increase and installation. This includes backup rated indoor diesel generators; 480 volt, 105 degree liter alternator with main circuit breaker; standard cooling system; dual filters for data center operations; redundant starters; batteries and chargers; Critical exhaust silencer and flexible pipes; vibration isolators, free-standing daytime water tanks; block heaters; factory testing; on-site startup and testing; and two-year warranty. Common additional cost data center options include enhanced high ambient cooling systems, 80-degree rise alternators, low nitrous oxide engine emission calibration, Tier 4 certified or compliant exhaust emission systems, and uptime ratings. According to noise reduction requirements and functions, the price of an outdoor cabinet for 1000-2500 kW generators is between 100,000-500,000 US dollars. For 2750-3500 kW generators, the operating cost of the cabinet is US$200,000-600,000.

Cummins provides an onboard parallel system PowerCommand, which provides synchronization and load control functions for parallel generators without using the main controller. It provides real-time status of all alarms and operating conditions, and can be accessed from anywhere. The Cummins system also includes AmpSentry, which is an overcurrent protection system listed in Underwriters Laboratories that operates without a circuit breaker, which simplifies selective coordination to minimize false tripping possibility.

Generac only produces generators and provides a single-engine backup system with a capacity of up to 3 MW. Generac's innovations include on-board paralleling, which simplifies the paralleling of generators by eliminating the requirement for traditional switchgear and providing all components from the same manufacturer. This allows you to grow from smaller kW units that meet your initial power requirements to up to 100 MW with additional units. Generac specializes in alternators, silencing enclosures, extreme performance enclosures, various control systems and base fuel tanks of different sizes.

Diesel has always been the traditional choice for generator fuel, but Generac focuses on smart grids, grid reliability and environmental regulations in its products. Natural gas and dual-fuel generators can extend the operating time and provide longer protection for facilities during crises. Compared with diesel, gas and dual-fuel generators also emit fewer emissions. Generac is the only supplier that provides dual-fuel generators that are fully integrated from the factory and comply with EPA standards.

Kohler designs and manufactures its own alternators, fuel tanks and engines, but also manufactures its own switchgear, controllers and enclosures to fit all generator size ranges. Kohler's 4 MW products have passed Tier 4 certification and adopt a selective catalytic reduction emission control system to reduce exhaust after-treatment components. This makes it cheaper and easier to maintain. The enclosures have passed IBC seismic certification, 186 mph wind load rating and UL 2200 certification.

An application engineering team provides complete system integration from the factory. All products comply with ISO G3 standards. Sales and service are run through a global network of distributors.

Regulation. The National Electrical Code requires buildings to have life safety systems to support safe evacuation. When a single generator can meet this requirement, life safety takes precedence over the basic system. You should put your life safety on a separate generator. As long as you electrically isolate the functions, this independent generator can also be used as a redundant generator for mission-critical systems.

The generator is resized. The manufacturer provides software to help adjust the size of the generator. Excessive scale can cause costly mistakes to the organization. Use multiple smaller generator sets to handle future growth expectations.

Reliability and availability. Reliable generators can be started within 10 seconds and provide power during power outages. If something trips the circuit breaker, the critical load may not be able to use the power supply. Isolate life safety, cooling, and IT loads on different generators to maintain availability.

Redundant configuration. In a redundant system, all generators should be started at the same time after a power failure, and shut down when the power has stabilized. Parallel generators that synchronize immediately and provide maximum initial capacity provide the best approach. In order to handle the inrush current from chillers, air conditioners and UPS systems, you usually have to increase the size of a single generator, which may be more costly than parallel smaller redundant units-especially if you can use onboard in parallel. Onboard parallel is simpler than external parallel gears, and the complete system can be fully factory tested before shipment. It also makes it easier to add generators and reduce commissioning time. Another method is to use a stepped transmission system to prioritize the loads and separate them for a few seconds to minimize the initial load surge.

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