Diesel Generator Failure - The Common Culprits and How to Avoid Them.

Year upon year the expectancy of constant reliable power increases, and the strain of such demands is felt throughout the power generation industry. Businesses require unlimited access to sustainable power to ensure their organisation maintains a consistent state of operation, without the fear of power cuts disrupting crucial operating hours. Power cuts can cause extreme damage to a company’s reputation resulting in huge financial losses, which is why many organisations are investing in vital standby power.

Whilst standby diesel generators are a critical investment they come with a large price tag, and require professional maintenance and repair to ensure a healthy operational system. A lax in maintenance will only lead to generator malfunction and the generator investment will be worthless. Organisations must be educated in the basic generator functions and understand, how to properly execute maintenance and repair checks in order to save them unnecessary down time, due to system malfunctions. PPSPower are experts in generator maintenance, repair & Service and have comprised a short guide to the most common culprits effecting diesel generator reliability, and how to prevent them from effecting your gen-set systems.

Battery failure

Weak or undercharged starting batteries are the most common cause of standby generator failures, with 8% of all batteries failing due to sulfation build up.

Sulfation occurs when a lead battery is deprived of a full charge and sulfate crystals form to a stable crystalline. If the crystals are left for weeks or months they can harden and the large crystals will eventually reduce the batteries active material resulting in battery failure.

Prevention:

In order to prevent this one must apply a periodic fully saturated charge.

Low Coolant Level

Generator engines are designed to run at specific temperatures, with insufficient coolant in the engine it runs the risk of overheating and failing at the time it is needed most.

Prevention: 

Check coolant level in the radiator weekly and top up with the correct coolant for the engine. Visibly check the engine for any coolant leaks from the engine.

Load Bank Testing 

Diesel engines are designed to run at specific loads, not running your generator at 70 / 80% load or full power at least once a year can cause damage to injector units which will inevitably end in damage to the engine. Fuel contamination of the engine oil is just one.

Prevention:

Annual load bank testing can determine if there is a failure and or could be, also operating cooling system and other engine parts to their full potential and burning off any unnecessary carbon build up in the engine from light load running.

Fuel Contamination 

Fuel contamination occurs when debris and other stagnant matter build’s up within the fuel tank, which can also cause excess water to build up and fuel bugs to grow.

Prevention: 

Regular fuel polishing and maintenance of the tank is the best prevention for this. More so on standby generator units.

Breakers and switches 

Sometimes human error comes into play and during maintenance routines the control panel may be left not in Auto mode and the output breaker left in the wrong position.

Prevention:

When any maintenance checks have been commissioned always check the output breaker is in the on position and the control panel is in auto mode.

Now for the salesy bit:

Within a PPSPower maintenance, repair and service visit we carry out the necessary checks which include all of the above and the following services:

24 hour cover - 365 days a year.

A dedicated Account Manager to ensure your needs are understood and responded to swiftly and efficiently.

Bi-Annual generator service visit (Major & Minor Services available).

Electrical engineering shop for design, build and upgrade of control panels.

Fuel and oil checks.

Lubricating system checks.

Cooling system checks.

Control Panel & Instrument checks.

Exhaust system checks.

Engine electrical system checks.

Alternator checks.

General Maintenance.

Full service documentation, sent immediately after the visit via email.

Recommendations for remedial work or generator repairs.

Tailored generator servicing packages to suit your business.

A vast range of critical spares in stock and ready to be dispatched the same day if required.

All Makes & Models can be dealt with including SDMO, Lister Petter, Cummins Generators, Petbow Generators, FGWilson Generators, Adept Power, Central Power, WBPS Generators and many more.

We also have the expertise to service Gas Generators, Fire Pumps and UPS systems and can offer discounted ‘all in’ packages.

Our own fleet of mobile resistive load banks for load bank testing.

We have a fleet of containerised generators available for long or short term hire.

PPSPower's sister company YorPower is a manufacturer of high quality diesel generators. All of our contract holders have preferential rates and availability to brand new diesel generators.

Call the team at PPSPower: 0345 200 9888