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There's a special kind of dread that comes with finding metal shavings in your generator's oil pan. That unmistakable sign of internal engine breakdown couldn't have come at a worse time for our critical broadcast site.
The story of our Cummins 400kVA generator is one of changing technology and infrastructure planning challenges. Installed around 2002, this diesel workhorse was appropriately sized for an era of power-hungry tube transmitters that could each draw 30-50 kilowatts. Fast forward to today, and our modern solid-state equipment—a 32kW TV transmitter, two FM transmitters (18.5kW and 3.6kW), and a 1kW NOAA weather radio transmitter—barely scratches the surface of what this generator was designed to handle. Our monthly power consumption rarely exceeds 200 kilowatt hours, even in peak summer months.
This mismatch creates a perfect storm when equipment failure looms. Do we rebuild this oversized dinosaur or replace it entirely? The economics favor replacement, but that means navigating a labyrinth of quotes, load calculations, site drawings, zoning approvals, and emergency contingency plans—all with a 6-12 month lead time hanging over our heads. Meanwhile, we're stuck in infrastructure limbo, hoping our metal-shedding generator keeps breathing long enough for procurement to work its magic. The stakes couldn't be higher: this site houses critical communications infrastructure serving entire communities with television, radio, weather alerts, and emergency communications.
Have you ever faced a similar infrastructure challenge? Share your generator breakdown stories or replacement nightmares with me—the link to text me is in the episode notes. Until next time, stay redundant, stay resilient, and when your generator starts coughing, don't just turn up the radio to drown it out.

🎙️ Need a voice tracker for your station? I’m Tyler — experienced in rock and classic hits, but open to other formats (no polka, thanks). Fast turnaround, easy to work with, and budget-friendly. Hit me up: [email protected]

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Got radio or TV engineering stories? Or just curious how the magic behind the mic and screen works? Whether you're in the biz or just a fan, let’s connect. Reach out on Bluesky—I'd love to hear from you!