Emergency and prime power commercial generator sets are important for data centres, manufacturing plants, hospitals, commercial buildings and construction sites. Unexpected equipment failures can have serious financial, operational and safety consequences.
Daily visual inspections are the first line of defence when it comes to avoiding failures. Before each startup, operators should check for fuel leaks, coolant leaks, oil leaks and loose wires. Also, while the generator is running pay attention to any strange noises, vibrations and colour changes in the exhaust. Do all instruments provide stable voltage, frequency and temperature? These are all things to monitor as the generator runs. Lastly, the EN ISO 8528-13 safety standard requires that all access panels and safety guards are securely fastened and closed to avoid hazards. Routine inspections significantly reduce unplanned outages and extend the operational life of the equipment.
The longevity of your engine heavily depends on the lubrication system. Maintain the lubrication system by keeping oil levels topped up and changing oil with brands recommended by the manufacturer that are suitable for the conditions in which your engine operates. At intervals of 200 to 250 hours of use replace oil and oil filters. For standby units that are rarely used for long periods do this every 6 months. Ensure that you do not have dirty oil in your engine. This increases the rate of wear on the engine bearings, and on the cylinders and other moving parts. When changing oil, do not forget to inspect the oil for the presence of metal parts that may be due to wear, or the presence of discolored oil, or other contaminants. This will show that your engine has internal mechanical issues that need to be addressed. Compliance with the lubrication specifications of the OEM for your engine indicates that your engine will be optimally functional and that the engine will also be in compliance with the quality management for ISO 9001.
The presence of clean fuel as well as good and unrestricted fuel further boosts the efficiency of combustion and the resultant power to the engine. Fuel tanks that are contaminated with water and sediments should be emptied of such materials, while fuel filters should be replaced as per the schedule. When fuel is of poor quality, this results in dirty fuel injectors, difficult engine starting as well as poor engine power. Dust and other debris that block air filters is commonplace in industrial areas and results in restricted access to air. Because of this restriction, more fuel is consumed by the engine and the temperature of the exhaust gases increases.
We recommend regular load testing as it can provide scenarios of what the real challenges may be. No load testing is best done monthly while full load testing is done quarterly. Make a service schedule that specifies engine belt and valve clearance adjustment, fuel injector resetting as well as a check of all the electrical components. To be compliant with legislation, the service must be performed by an authorized service provider. Having services performed by an authorized service provider minimizes the risk of major breakdowns.
Achieving lower costs and improved returns on your investment requires a consistent approach to upkeep. TorchPower is committed to providing the best customer support, providing generator sets with advanced technology and a range of 24/7 after-sales support to ensure operational excellence. Businesses can combine proper maintenance with improved manufacturing support to ensure uninterrupted cost-effective critical service power.
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