Industrial Power Generators | Backup Generators

Power Your Jobsite

Mobile Power Generators

Designed for Moving

Available in either a trailer or skid mount configuration, the Horton mobile generators are designed for safe and easy movement and adaptable to whatever the job site demands. Compact for better maneuverability, they offer efficient transportation with more units per truckload resulting in lower transportation and storage costs.

 Rustproof Canopy

Horton industrial power generators are fully protected by heavy-duty, weatherproof, enclosures that feature an integrated door sealing system comprising a unique foam and seal layering structure to ensure a watertight seal and improved sound attenuation. The Horton anti-rust canopy has a unique “no weld” corner design to eliminate traditional rusting spots. Furthermore, the spillage-free frame, which is standard across all models helps to minimize environmental impact.

 Full Control

Intuitive but simple controls, with easy-to-read display and customizable menus, put the operator in complete control of functions, Horton controllers feature the latest technology including advanced warning and alert parameters.

Overall, the new plug-and-play Horton power generators offer a combination of reliable engine power, compact design, 500-hour minimum maintenance intervals, simple paralleling, and long service life. Optimum fuel savings and better fleet utilization contribute to increased revenue for mobile site and industrial plant operators.

Fixed Power Generators

Dedicated fixed industrial power generators offer full support for facility power management. With the DAE Pumps fixed power generators, you still can move containers to wherever they are required. These power generators provide variable power needs that can be used in industrial power plant, oil & gas, mining and at events.

The DAE Pumps container-sized generators come with two generators inside capable of operating independently or in parallel with each other, providing multiple solutions and combination between prime and standby use.

Diesel Powered Generators

Our diesel-powered generators are prime power, multi‐voltage, sound attenuated, mobile generators. They are powered by a John Deere Tier 4 Final, liquid-cooled, four-cylinder diesel engine. The units consist of an alternator, diesel engine,
cooling system, electrical distribution, and control systems ‐ all enclosed within a sound attenuated enclosure fabricated from powder-coated steel with zinc-rich primer. 1000 hr salt spray test. A broad range of undercarriage formats and options are available.

Special attention has been given to the overall product quality, user-friendliness, ease of serviceability, and economical operation to ensure the best in the class total cost of ownership.

Selecting a Jobsite Power Generator

The critical parameters for sizing an industrial power generator all start with the load to be served. These parameters include: the size of the load in kW and kVA; the maximum allowable voltage and frequency dips that the load can withstand; the type of load, such as motors, lighting, UPS, VFD, etc.; the character of the service expected of the generator, which means is this a standby power application or is the generator to be the only power supply for this load; any requirement for spare capacity for the future loads; and, of course, voltage, phase, and frequency requirements. All of these parameters can affect the generator sizing.

A generator’s continuous, prime, or standby ratings pertain to the definition of duty for which the generator will operate. Operating above these rating definitions will result in shorter life and higher generating costs per year. Below are general descriptions of duty ratings as described by a generator manufacturer (Caterpillar). Depending on the manufacturer, the actual definition may vary from the general definitions presented below.

• Standby Rating: Output available with varying load for the duration of the interruption of the normal power source. The generator with the Standby Rating is typically used for the building standby power services. (Typical Load Factor = 60% or less; Typical Hours per Year = 500 h; Typical Peak Demand = 80% of standby rated kW with 100% of rating available for the duration of an emergency outage. )
• Prime Rating: Output available with varying load for an unlimited time. The generator with the Prime Rating is typically used for heavy industrial loads, pumping station applications, peak shaving applications, or cogeneration plant applications. (Typical Load Factor = 60% to 70%; Typical Hours per Year = no limit; Typical Peak Demand = 100% of prime rating used occasionally. )
• Continuous Rating: Output available without varying load for an unlimited time. The generator with the Continuous Rating is typically used for utility parallel operation, on-site generation, or baseload cogeneration plant applications. (Typical Load Factor = 70% to 100%; Typical Hours per Year = no limit; Typical Peak Demand = 100% of continuous rating used 100% of the time. )

Operating a generator beyond the constraints for which it was designed will result in a shorter life and increased operating and maintenance costs.

Applications of Diesel Powered Generators

Mobile and fixed industrial power generators are used in a variety of applications including:

• Chemical
• Oil
• Coal Ash
• Fly Ash
• Barge Offloading
• Tank Clean-out
• Pond Cleaning
• and many more

Industrial Power Generator Ratings

The most common ratings for industrial power generators are standby and prime ratings. A standby rating is intended for supplying emergency power for the duration of a normal utility power source failure. There is essentially no overload capability for a standby-rated generator. Prime rating is the maximum power available at a variable load for an unlimited number of hours. In addition, a 10% overload capability is also available for a limited time. Limited run time and baseload (continuous) are other examples of generator ratings but are less commonly specified. These ratings are defined by international standards that all manufacturers are required to follow in regards to published performance data for their equipment.

Generators’ ratings are based on their capability of delivering a specified amount of power for the duration or number of hours per year anticipated. In general, an industrial generator can deliver more power for a limited amount of hours per year, or less power continuously. The duration of anticipated generator use throughout the year is a key factor in choosing the appropriate rating. Determining whether a normal utility source (or other reliable power sources) is available or if the generator is the only source of power for the site is another key factor. Many generators have both standby and prime ratings for the same set, so the portion of continuous and variable loads also needs to be considered and evaluated to determine which size would be applicable for each rating.

Applicable codes are another factor in determining generator size ratings. Emergency systems (NEC 700) are required to be sized for connected load unless the application is an NEC 517 healthcare application; in that case, the load is sized based on anticipated load levels and prudent design. If the application is NEC 701 legally required systems, the generator is sized for loads that are expected to operate at one time. For optional standby sizing, the code requires compliance with NEC 220 calculations or another authority having a jurisdiction-accepted load calculation/sizing process.

Spare or future capacity must also be considered when making initial Genset selections or recommendations while balancing the owner’s first cost and long-term needs.

Industrial Generator Safety

Skid Mounted Unit
Units must be set on a solid, level surface capable of supporting the generator set during operation. When placing a unit, an approved lifting apparatus (fork truck or crane) must be used. Automatic transfer switch sizing and conductor sizing must meet NEC standards. Fuel is supplied from a remote location (diesel or natural gas). Exhaust must be insulated and routed out of the building to the atmosphere.

Mobile Unit
The unit must be located on a solid surface and leveled. Mobile units are completely self-contained and can be transported with fluids. Temporary Cable must be located out of traffic area. The industrial generator can be connected to the automatic transfer switch or load using an approved manufacturer’s plug or using individual electrical lugs that connected to terminals.

Generator Startup

When the generator is ready for start-up and load manufacturer’s recommendations must be followed for the unit. Remove all tags and locks from equipment installed during connection. Permanent units are shipped without fluids, while mobile units can be shipped with all fluids.

The basic rule of thumb checks for start-up operations for mobile units are:

1. Verify all electrical connections are correctly connected and tight.
2. Check fuel, oil, and coolant levels. Verify air filter indicator is green and operable.
3. Start the engine and check for fuel, oil, exhaust leaks, and louver operation.
4. Make sure no engine or generator alarms exist.
5. Load generator set and make sure all operating parameters are correct.

The basic rule of thumb checks for start-up operations of permanent units are:

1. Verify all electrical connections are correctly connected and tight.
2. Fill engine with oil, coolant tank with coolant, fill the fuel tank with fuel.
3. Verify fuel line is connected from fuel tank to engine.
4. Verify air filter indicator is green and operable.
5. Prime fuel system (engine fuel systems without automatic prime functions).
6. Start engine, check for fuel, oil, and exhaust leaks. Make sure no engine or generator alarms exist.
7. For canopy unit installations, check louver operation.
8. Run the engine until the operating temperature is reached and shutdown.
9. After the engine cools down, check and oil level and coolant level. Add fluid where needed.
10. Load generator set and make sure all operating parameters are correct.

Relocating your Generator

In some cases, it may be necessary to change generator set locations on a site. When changing the location of a generator set consider the following:

• Reduce the number of moves by positioning the generator in a location accessible by multiple locations.
• Inform all users of loss of power due to generator move.
• Always disconnect from the power grid prior to shutdown.
• Locate on solid level ground.
• Route power cable out of high traffic areas.
• Connect the cable to the generator and automatic transfer switch.
• Start and load generator.

Advantages of Owning a Generator

Long-term use is a primary reason for purchasing an industrial power generator set. Selecting the proper size and generator rating is imperative when designing the power generation system.

A rule of thumb for ratings is:

Emergency/Standby – Used when utility power fails
Prime – Used approximately 8 hours per day
Continuous – Continuous operation. Shut down for maintenance
Establishing the properly rated generator for the application is an important part of the advantage’s equation. If an improperly sized or rated generator is installed, the system may not perform to expectations, experience a greater failure rate, or both.

Once the correct generator is selected and installed some key advantages of purchasing are:

Asset Ownership – You own the equipment and are not locked into rental agreements, set time periods, and can also resell it if desired.

Savings vs. Long Term Rental Costs – When renting a large commercial generator over many months the cost can escalate fast. This is where it is helpful to look at all the possible scenarios and do the math on how much it costs for extended rentals with monthly breakdowns, and also consider what happens if you need the industrial generator for longer than initially planned (which is quite common).
You Control Power Availability – Emergency, prime, or continuous power in a permanent installation is not controlled by a rental contract. Your facility is also never limited in the event that local rental generators may not be available during peak rental times (like hurricanes and major power outages).

No Ongoing Maintenance Fees from Rental Providers – If you are a heavy user and rack up the hours on a rental industrial power generator you will most likely be required to pay for all additional service provided to maintain the generator at set hour intervals (such as load bank tests and service), which adds to the cost of renting.

Internal Staff Maintenance and Repair Options – Facilities with a maintenance staff can elect to perform their own maintenance and repairs saving some cost. More advanced testing, such as load bank testing is still usually contracted out with a local service provider

Configuration Modifications – Every generator installation is different from the last, permanent installations require individual configurations that rental units often do not offer including things like the ability to customize wiring, fabricate custom ad-on, modify enclosures, and customizing exhaust systems and fuel tanks just to name a few.

External Vendor Maintenance and Repair – For facilities with limited or no maintenance personnel, the most qualified local generator service provider can be used.