Industry: Oil and Gas
Location: Weld County, Colorado
Service Provided: Fuel System Diagnostic, Regulator Evaluation, Start Failure Troubleshooting
Overview
An oil and gas operations site contacted Generator Source after experiencing repeated start failures on a natural gas generator that supported critical field operations. The generator displayed intermittent overcrank errors, slow cranking, and inconsistent starting performance. Previous service attempts focused on regulator adjustments, but the issue continued to return. Generator Source performed a deeper evaluation and uncovered a root cause tied to gas supply conditions at the site.
The Challenge
Field operations rely heavily on reliable standby and prime-assisted generators. The customer had experienced start failures over several months and had multiple technicians attempt onsite corrections. The unit showed symptoms including failure to start, overcrank errors, slow cranking, and unpredictable behavior. The customer shared that multiple pieces of equipment were tied into the same gas supply line, creating load competition that may have been starving the generator during starting conditions.
Our Assessment
Generator Source reviewed historic service records and confirmed that the generator’s performance issues consistently aligned with fuel supply conditions rather than mechanical failure. The site’s natural gas system fed several other production-related devices that consumed significant load. As demand fluctuated throughout the day, the generator’s inlet pressure dropped too low during cranking. The previously installed secondary regulator helped temporarily but could not compensate for inconsistent upstream pressure. Generator Source identified the shared gas line and unstable inlet pressure as the primary cause of the intermittent failures.
The Solution
Generator Source performed onsite diagnostics to temporarily stabilize the regulator and confirmed the generator could be brought online for immediate operations. The team recommended installing a dedicated gas line for the generator to ensure consistent pressure during startup, reduce overcrank events, and improve reliability. The service coordinator prepared documentation for the customer and emphasized the importance of stable fuel supply for natural gas generator performance. The senior technician also identified long-term monitoring steps for future PM visits.
The Result
The oil and gas operator gained a clear understanding of why repeated adjustments had not solved the problem. With the recommended changes, the customer was able to temporarily stabilize operations and began evaluating infrastructure updates for a dedicated generator fuel line. Generator Source provided documentation for internal engineering teams, improved confidence in the unit’s long-term performance, and prevented unnecessary parts replacement by identifying the actual cause of repeated failures.
Why It Matters
Oil and gas operations depend on continuous power to support pumps, controls, data systems, and safety-critical equipment. Natural gas generators are highly sensitive to inlet pressure during starting conditions. When multiple high-demand systems share a fuel line, even minor fluctuations can create overcrank errors, hard-start conditions, and failed runtime events. Identifying fuel supply issues early prevents costly downtime and unnecessary component replacement.
Experiencing inconsistent starts or overcrank alarms at your O&G site?
Generator Source provides full fuel system evaluations, regulator diagnostics, and reliability assessments for natural gas and diesel generators. Contact our technical services team to schedule a field diagnostic today.