As power generators are responsible for supplying much-needed energy to power crucial equipment, especially during a power outage, the importance of proper generator maintenance cannot be overstated. In fact, it is essential for organizations that rely on emergency power systems, such as data centers and hospitals, to ensure their generators remain in prime condition at all times.
However, some end-users do not think to maintain or service their equipment regularly, as they may view this process as time-consuming and an unnecessary expense. Moreover, in the case of backup generators, which are often left idle until a power outage occurs, they may not even consider that maintenance is required since it is rarely used.
The Importance Of Maintaining Your Power Generator
Generally, there are two types of generators –Prime Power application and Emergency standby application. The former is usually used as a site’s primary source of continual power and is designed to support critical operations long-term, offering a variable power load that is drawn over time. Meanwhile, as its name suggests, the latter is for emergency use only.
The maintenance process for both generators is essentially the same. Although, prime generators require more frequent servicing due to their heavier workload. Failure to maintain either generator can lead to dire consequences, as even a defect in a single component is sufficient to render the equipment useless. Therefore, it is recommended that you schedule regular maintenance and upkeep of the equipment to ensure it remains in working condition and is ready to go when the need arises. If not, you will encounter the following issues.
1. Costly Repairs
Just because your power generator is not displaying any signs of failure or defect does not mean a problem does not exist. While you may think you are saving money by skipping routine maintenance, the issue could escalate and spiral out of control. When this happens, you may need to replace a component or overhaul the entire generator, causing you to end up spending more on repairs.Â
To avoid incurring additional expenses on repairs, your best option is to implement routine maintenance checks of your equipment. They can help detect electrical and mechanical issues early on, allowing the maintenance crew to effectively address them early to prevent costly repairs down the road.
2. Power Failure
Your generator is meant to provide safe, reliable, and uninterrupted power. However, a lack of maintenance can ultimately lead to power failure – the very thing you were relying on the equipment to avoid. As a result, your crucial operations will grind to a halt, resulting in significant losses.
3. Exposure To Hazardous Work Conditions
Foregoing proper generator maintenance is not only costly. It can also endanger the safety of your work environment and workers. For example, if the fuel were to leak onto hot engine parts when in use, it could result in a fire. A timely maintenance check can allow the technician to spot and repair the leak, preventing an accident from occurring.
What To Take Note Of During Generator Maintenance
To ensure you always have sufficient power when you need it, regular servicing is critical. However, there are several vital components you must take note of during maintenance to ensure your equipment is always ready and running when the need arises.
1. Fuel
The fuel used for powering your generator comprises various components. Over time, these substances oxidize, causing them to form viscous deposits that do not burn efficiently, if at all. When you neglect to replace the fuel, the impurities mixed within it will be deposited throughout the generator’s system, clogging up its fuel injectors and fuel injection pumps, thus causing it to run inefficiently or fail altogether.Â
The same goes for the fuel filter, which is responsible for blocking dust and other harmful particles from entering the engine. If you fail to replace the fuel filter promptly, or worse, utilize an ill-suited component, some of the impurities will infiltrate the engine and cause potential damage to the fuel pumps and injectors, affecting its performance and causing fuel starvation to occur.
In addition, you must keep a lookout for fuel dilution, which can occur when diesel fuel infiltrates the engine’s oil sump and contaminates the engine lubricating oil. During the service life of the engine oil, some amount of fuel dilution is inevitable. However, several factors can cause excessive dilution:
- Excessive carbon or leaking fuel injectors
- Excess idle time
- Incomplete combustion
- Low operating temperatures
- Worn piston rings/excessive blow-by
This issue usually happens over a period of time and can contribute to significant wear to the engine. If routine maintenance is overlooked, it can damage the engine.
2. Battery & Electrical Components
The battery and the various electrical components within a generator have a fixed lifespan, between two to three years, depending on the manufacturer. Therefore, we recommend inspecting them at least once or twice a month to ensure they are still functioning normally. Understanding the lifecycle of the various parts and checking their performance regularly will ensure you replace any faulty components as soon as possible, preventing further issues from cropping up.
3. Air Filter
Diesel power generators require fresh air for the combustion process. The air filter will sift out unwanted particles, preventing them from entering the combustion chamber. When the air filter reaches its capacity, it must be replaced as per the maintenance log, or your generator will become less efficient, thus resulting in a greater consumption of fuel.
Tips For Maintaining Your Power Generator
When your generator is correctly cared for, it can potentially provide many years of utilization Let us share how you can keep your equipment in tip-top shape.
Learn More: The Ultimate Guide To Maintaining Your Industrial Generators
1. Ensure Proper Housekeeping
Environmental factors can damage your generator in the long term, which is why regular maintenance is essential. However, maintaining your generator should not only pertain to repairing or servicing the equipment. How you store your generator also plays a pivotal role in ensuring it remains in perfect ideal working condition.
The area where the generator is installed should be kept clean at all times to minimize the risk of pests, like rodents, infiltrating and damaging its wires and components. In addition, ensure the surrounding area and equipment are kept dry to prevent moisture from causing corrosion.
2. Conduct Daily Visual Inspections
Conduct a visual inspection of your generator daily, even if it is not in use frequently. Doing so can help you detect possible signs of damage early, ensuring prompt maintenance before the condition deteriorates, leading to more costly repairs or replacements
3. Avoid Running The Generator Without Load Or With Low-Load.
While manufacturers often recommend starting up standby generators and allowing them to run for a few minutes to keep components lubricated and ensure the equipment is functioning correctly, avoid running it without load or with low load for an extended period. Doing so can cause wet stacking — a condition where unburned fuel passes into the exhaust system.
Like all internal combustion engines, a diesel power generator must maintain the correct air-to-fuel ratio and be able to sustain optimal operational temperature for a complete burn of fuel to operate at maximum efficiency. However, it will not attain its correct operating temperature when it operates on a light load. When this occurs for extended periods, unburned fuel will be present in the exhaust manifold. Hence, the phrase ‘wet stacking’.
As the unburned fuel begins to accumulate in the exhaust side of the engine, it will result in fouled injectors and a buildup of carbon in the internal combustion components. These excess deposits can affect the engine performance, as gasses bypass valve seatings, exhaust buildup produces backpressure, and deposits on the turbo blades reduce turbo efficiency. Over time, the deposits will scar and erode crucial engine components surfaces.Â
Moreover, when the engine is running below the designated operating temperature, the piston rings do not expand adequately to seal the space between the cylinder walls and pistons. That leads to unburned fuel and gasses escaping into the oil pan and diluting the lubricating properties of the oil, causing premature engine wear.
However, with the emergence of newer engines with improved technologies and tighter tolerances, the possibility of wet stacking, fuel leakage etc. are greatly reduced. This allows more flexibility in the maintenance schedule and loading running. More details can be found in the KD Series Generator Conscious Care Program.
4. Avoid Attempting Repairs On Your Own
We recommend hiring
a professional to conduct regular maintenance of your generator, as they will
possess the relevant technical knowledge and understand how to service the
equipment. Attempting repairs on your own can cause more harm than good if you
or your staff do not have the correct knowledge and
tools to carry out the repair. You will also spend more money than necessary to
get the issue resolved.
Keep Your Power Generator Running Smoothly With Rehlko’s Maintenance Plan
With proper maintenance, your generator can last for years, safeguarding your operations in the event of a power outage. All you have to do is be mindful of what the equipment needs and be proactive about servicing it before issues surface.
At Rehlko, we offer a one-stop maintenance solution for different Rehlko generator models, providing technical expertise and quality components that meet the highest standard for operation and durability.Â
Alvin Lin
He is an Aftermarket & Service Training Senior Engineer with Kohler Power Systems. He has been with Kohler since 2016 and supports South-East Asia regionally. He has a wealth of hands-on & troubleshooting experience with power generators and large diesel engines, specialising in Kohler KD Series Engines.
Francis Christopher
He is an Aftermarket & Service Training Field Service Engineer at Kohler Power Systems. He has been with Kohler since 2019 and oversees Southeast Asia Industrial and Marine applications. He has extensive experience with engine and control systems, stand-alone gensets, and multiple genset installations involving synchronization and paralleling operations. Furthermore, he commissions, troubleshoots, maintains and repairs all Kohler power generator products.
