Backup Generator Mistakes Ohio Businesses Make
The short answer
Backup generators fail when they're needed most for predictable reasons: they weren't sized for the loads that matter, weren't tested under load, ran out of fuel, or the transfer switch didn't work. A short annual review fixes most of these. Generators can also help your electricity costs — through PJM demand response or peak management — but only within air-permit and safety limits.
Eight common mistakes
- Sizing for the whole building instead of critical loads (or the reverse). List what must run: refrigeration, IT, life safety, key process equipment.
- No load-bank testing. Monthly no-load exercise isn't enough; test under real load periodically.
- Fuel assumptions. Diesel degrades; natural-gas supply can be interrupted in extreme cold. Know how many hours you have and how you'll refuel.
- Transfer-switch problems. Automatic transfer switches need maintenance and testing too.
- Motor-starting surprises. Large motors can stall a generator on start-up; stagger restarts.
- Ignoring permits. Ohio EPA air permits and federal engine rules limit non-emergency run hours for many units.
- Load spike on return. When power comes back, everything restarts at once — setting a new demand peak. Program a staged return.
- No written plan. Who starts what, who calls whom, and what gets shed first.
Can a generator lower my electric bill?
| Use | Potential benefit | Constraint |
|---|---|---|
| PJM demand response (via a curtailment service provider) | Payments for reducing grid load during events | Engine permits and emergency-only rules |
| Capacity-tag management | Lower tag = lower generation cost next year (≈ $120/kW-year at 2026/27 prices) | Must run during the right summer peak hours |
| Monthly demand shaving | Lower delivery demand charges | Run-hour limits; fuel and maintenance cost |
Batteries are increasingly used for the same purposes without emissions limits — see energy storage best practices.
FAQ
How big a generator does my business need?
Size it for the critical loads you've listed, including motor-starting requirements; an electrician or engineer should confirm.
Can I use my emergency generator for demand response?
Sometimes, but engine permits and federal rules may restrict non-emergency operation. Check before enrolling.
How often should a generator be tested?
Follow the manufacturer and code requirements; many sites exercise monthly and load-test at least annually.