One of the most frequent applications we’re asked about at ETTER is: “Can you supply a booster for my generator that requires higher gas pressures — 2 PSIG and above?”
The short answer: Yes, but higher pressures come with hidden costs and design considerations that engineers should understand before specifying equipment.
Why Pressure Requirements Vary by Manufacturer
Not all generators are created equal.
Generac and Kohler: typically require only ~½ PSIG (14” w.c.).
Other manufacturers: may call for higher pressures (2 PSIG+).
This difference matters. In many U.S. markets, gas utilities deliver around 2 PSIG, but in others—such as Boston—supply can be as low as 4” w.c. (0.14 PSIG).
In low-pressure markets, boosters are not optional—they’re required. But the higher the target pressure, the larger the booster horsepower required.
How Booster Horsepower Scales With Pressure
The relationship is not linear—higher pressure requires dramatically higher booster horsepower.
20,000 CFH at 13” w.c. boost → ~1 HP booster
20,000 CFH at 42” w.c. boost → ~10 HP booster
That 10x jump in horsepower has big implications:
UPS Battery Backup: The UPS required for a 10 HP booster can cost 4x more than one for a 1 HP unit.
Lifetime Operating Costs: Running a 10 HP motor continuously adds significant energy and maintenance expenses.
The Hidden Heat Problem
With higher horsepower comes more heat:
Electrical heat from the motor itself
Heat of compression as gas is pressurized (similar to how an air conditioner cycle generates heat)
In low-flow conditions, a 10 HP booster can push gas temperatures to 200°F+.
While this isn’t an explosion risk, it does create safety and equipment design challenges. To manage it, high-HP boosters require a fan-cooled heat exchanger (FCHE) package, often costing upwards of $7,000.
The Bottom Line for Generator Projects
High-pressure boosters for generator applications are possible, but they are:
- More expensive upfront (double the cost of smaller boosters)
- More complex to operate (added cooling, larger UPS requirements)
- Less efficient long term (higher energy consumption, more maintenance)
Closing Thoughts
Before specifying a high-pressure generator, it’s worth asking:
Does the generator really require 2 PSIG+, or could a lower-pressure unit meet the project need?
Could the project save significantly by selecting a generator that aligns with standard utility pressures?
ETTER has specialized in generator booster applications for decades. Our role isn’t just to provide equipment, but to make sure engineers and owners understand the full cost and design implications of their choices.
If your project involves generator gas supply, our team can help you evaluate whether a high-pressure booster is truly required—or if a smarter alternative exists.
