Case Studies: How Our Field Engineers Prevent Equipment Breakdowns

Diesel generators are complex machines with over 30,000 parts, requiring both mechanical and electrical expertise to maintain and operate effectively. These generators are crucial in providing an external power source when there is no power or when heavy loads are needed for tasks such as industrial operations. Preventing downtime is paramount, as these generators are relied upon in critical situations.

Field engineers specializing in diesel generators need a unique set of skills that are typically restricted to OEM plants or specialized courses. At EAMOT, we offer comprehensive training programs in collaboration with SSRDP, equipping our engineers with the necessary knowledge and practical experience.

The Challenge

Understanding the patterns of load, current, frequency ,oil pressure , coolant temperature and fuel consumption based on the rating of the diesel generator set (DG Set) is essential for accurate diagnostics , maintenance & savings. Issues can range from battery drainage to controller malfunctions, with resolution times varying from a day to a month depending on complexity. The diesel generator industry is heavily influenced by OEMs, which often oppose the Right to Repair initiatives. This opposition can lead to monopolies on parts, resulting in expensive and delayed repairs due to parts shortages.

EAMOT's Training Approach

EAMOT's field engineers undergo rigorous theoretical and practical training before assisting senior field engineers in the field. Our training program includes:

• Dismantling and Integrating Diesel Generators: Students learn how to take apart and reassemble DG sets in our labs.
• Safety Handling: Proper handling of equipment and safety practices are emphasized and practiced.
• Controller Understanding: Engineers are taught to interpret controller parameters, which are then fed into an app for senior agent analysis, ensuring faster resolutions.
• Supply Chain Integration: If a part needs repair or replacement, it is immediately sent to the supply chain department for order and dispatch, preventing lengthy waiting times.

Case Study: Haryana Site

The Situation

In one instance at a commercial site in Haryana, an EAMOT field engineer demonstrated the effectiveness of our training program. The site was heavily reliant on a diesel generator to maintain operations during frequent power outages. When the generator failed to start during a scheduled power cut, it posed a significant risk to the site's operational continuity.

Diagnosis and Resolution

Upon arrival, the engineer conducted a preliminary inspection and utilized the Diesel Generator Monitoring System (DGMS) integrated with IoT. The DGMS provided real-time data on load patterns, current fluctuations, and fuel consumption. Analyzing this data, the engineer identified a pattern of erratic load behavior indicating a potential controller fault. Additionally, historical data revealed frequent battery drainage issues.

Using his training, the engineer performed a detailed diagnostic check on the controller and battery system. He discovered that the controller's firmware needed updating, and the battery connections were corroded. The engineer updated the firmware and cleaned the battery terminals. The generator was tested multiple times under various load conditions to ensure stability.

Leveraging IoT for Preventive Maintenance

The DGMS played a crucial role in this process by providing:

• Real-Time Monitoring: Continuous data on generator performance, highlighting anomalies.
• Predictive Analytics: Historical data patterns predicting potential failures.
• Efficient Troubleshooting: Pinpointing exact issues, reducing diagnosis time.

Impact of the Resolution

The successful repair and optimization of the generator had immediate and long-term benefits:

• Immediate Impact: Restored power during outages, ensuring uninterrupted site operations.
• Long-Term Benefits: Improved generator reliability, reduced downtime, and lowering maintenance costs.

Patterns of Diesel Generator Use

Understanding diesel generator use patterns is crucial for effective maintenance and operation:

• Load Patterns: Regular monitoring of load patterns helps in identifying whether a generator is under or over-utilized. Consistent load data can indicate the need for right-sizing the generator to match the site's energy demands.
• Current Fluctuations: Tracking current fluctuations helps in detecting irregularities that may indicate electrical issues or inefficiencies in power distribution.
• Fuel Consumption: Monitoring fuel consumption patterns can reveal inefficiencies or potential leaks, helping in optimizing fuel usage and reducing operational costs.

The Role of IoT in Diesel Generator Management

IoT technology has revolutionized diesel generator management by:

• Enhanced Monitoring: Providing detailed insights into generator performance and operational health.
• Predictive Maintenance: Using data analytics to predict and prevent potential failures before they occur.
• Optimal Sizing and Usage: Analyzing usage patterns to ensure generators are appropriately sized for their applications, leading to improved efficiency and longevity.

The expertise and training of EAMOT's field engineers, combined with advanced IoT technology, ensure that diesel generators are maintained effectively, preventing costly downtimes. Our approach not only addresses immediate technical issues but also contributes to long-term operational efficiency and sustainability. Through continuous training and the integration of technology, we empower our engineers to deliver exceptional service and support to our clients, maintaining the highest standards of reliability and performance.