GENSET PREVENTIVE MAINTENANCE

Preventive maintenance for generator set (genset) systems is an integral part of station operation. Engineers should do basic checks to ensure proper genset operation. The worst thing for a station is to discover that the genset does not work when it's needed most. Functionally, a genset is mainly composed of a dynamo and its prime mover, an engine. The engine supplies the mechanical energy, and the dynamo turns it into electricity. Maintaining the engine is similar to maintaining that of a vehicle, while maintenance of the dynamo is the same as for an electric motor.

The battery
The battery provides power to the engine starter. It should be checked at least weekly for its capability to run the starter. Check the battery terminals to ensure that they make a good mechanical and electrical connection to the starter and the charger. Maintenance-free sealed batteries are the best to use, but leadacid batteries can do the job at a lower cost. Just be sure to check the electrolyte levels of the lead-acid type on a monthly basis.

Coolant water
The coolant is usually composed of automotive-grade glycol to prevent freezing during winter. Check the level on the radiator on a regular basis, similar to what would normally be done on a car. Use a temperature gauge to ensure that the freezing point of the glycol mixture is much lower than what is required in the genset's location. Also, check the water hoses used on the engine for wear and cracks. Hoses can be deformed by old age and overheating, and they may need to be replaced before any serious leaks occur.

Clean air
Inspect to ensure that clean air gets into the engine through the air filter. If the genset housing has a window with a louver intake, make sure that this louver opens when the genset is operating. The mechanical arm can sometimes become so stiff that there is not enough air coming into the genset building. Also, a screen should be installed to prevent the intake window from being clogged by insects. This screen should be inspected regularly to ensure free airflow.

Engine oil
Preserve the genset engine by keeping an eye on its engine oil. Use the right grade and check regularly for the proper oil level. The oil filter should be checked and replaced at the same time as the oil is changed. The engine manufacturer should have recommendations as to how often the oil and filter need to be replaced. Ensure that the cap of the dipstick is properly replaced after every inspection to prevent spillage during operation.

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The fuel
Depending on location, diesel is economical in the long run for big generator sets, while propane provides longer hours for smaller gensets. The hours of genset operation need to be logged at least weekly and the tank reservoir inspected. If using propane, check for leaks with soapy water and a sprayer at least weekly.

The engine
Have a genset dealer or representative do a load bank testing of the genset once a year. This may also include compression and timing tests to ensure that the engine is operating at optimum performance.

The ATS
Mechanical parts of the ATS have a tendency to get stuck if not used regularly. Activate the automatic transfer switch (ATS) during a maintenance night to exercise it. Refer to the manufacturer's recommendations for proper lubrication of any moving parts. Use a laser-operated pyrometer to test connector temperature. This is particularly useful for determining if bolted connections for wires carrying high current are overheating. It enables the engineer to determine if the connection is overheating without making any physical contact with it, thereby making it a safe procedure.

The maintenance schedule

There is a suggested genset maintenance schedule. It is divided into frequency of implementation (weekly, monthly and annually). These frequencies may vary according to specific needs such as the age and size of the genset, its site location and available manpower. Develop a schedule that ensures optimum genset performance Implementing an effective preventive maintenance program on the genset system will prevent unpleasant surprises.

A genset system can be divided into two major parts: the dynamo that produces the electricity and the engine that moves it.

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A well-protected dynamo will rarely experience operational problems unless a catastrophic event burns the windings or loses one of the phases. Aside from monitoring the presence of all three phase voltages and current, there is not much on-site maintenance on the dynamo that can be done by station personnel. The engine, however, is a machine that requires more attention on a regular basis. There are several parameters to be observed and prerequisites to be satisfied to ensure that the engine will operate as expected. Just like maintaining a car, there are basic checks that need to be done to ensure that it will start when called for and keep on running as needed.

Systems check

The battery connections, electrolyte and charger are simple items to check. The engine requires proper and adequate cooling when in operation. Big engines, like those used to supply power to broadcast facilities, use air and water (glycol mixture) cooling. Adequate air should be present so as not to choke the genset while in operation. This means that air openings of the genset building are clear (louvers are open during operation) and that the air filter of the engine is not clogged. Installing an air-filter restriction indicator will facilitate inspection of the health of the air filter. The water coolant, usually a mixture of automotive glycol and water, should be at the correct level prior to genset operation. Because it is usually hard to determine the coolant level without opening the pressure valve on top of the radiator, it is best to install a sight glass for a quick inspection. Also, ensure that the coolant being used has the right freezing point for the geographic location. Check the glycol freezing point before winter comes and act accordingly. Also check the water hoses for the radiator for cracks or loose connections due to the steam temperatures they must endure during operation. It is best to inspect these on a regular basis because steam leaks can deplete the radiator of its coolant after hours of operation. Big engines require a starter motor to initiate operation. This starter motor requires the dc voltage supplied by the battery to run. Make sure that the battery can indeed make the starter motor run. This means that the proper battery should be in place and that it is regularly checked for its output voltage and ability to provide the required current. Take note that a battery may show the right voltage but its output is severely limited if there is a weak cell due to lack of electrolyte or damaged electrodes. A symptom of this is a drop in voltage under load. Similar symptoms will show also if the terminal connections are loose or corroded. Any checks performed on the battery should first determine if the terminal connections are intact and that the wires used are continuous. Check the battery charger as well to ensure that it is properly charging the battery. Although maintenance-free sealed batteries are best to use, the common lead acid batteries can do the job at a lesser price. Check the health and level of the electrolyte for lead acid types on a regular basis.

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Check all hoses and connections for leaks and cracks.

Check the fluids

The life of the engine can be severely shortened by lack of proper lubricating oil. Ensure that there is enough oil in the engine before operating it, taking note of the manufacturer's recommendations about oil and filter change and monitoring. This is one of the reasons why an hour meter is necessary to log the hours of operation of the engine. Properly reseat or reseal the cap of the oil dipstick after each inspection. This precaution prevents oil spillage during operation. Make sure that the fuel filter is replaced according to manufacturer's recommendation. Inspect the fuel lines for leaks and employ qualified personnel to do repairs as needed. This is more critical natural gas is used. Checks for leaks can be as simple as spraying soap water on pipe connections and watching for bubbles from escaping gas. Ice shields protecting fuel pipes should also be inspected before winter comes. Off course, you want to make sure that fuel is replaced when needed so regular checks on the fuel tank capacity should form part of the inspections.

Suggested maintenance schedule

This suggested schedule serves as an example. The final schedule for your installation may vary, and it's a good idea to have the schedule reviewed by the genset manufacturer or dealer to include factors that are appropriate to your genset model, size and age of the unit.

Daily:

Check fuel tank and record hour-meter reading. Refill fuel tank as needed. Inspect building interior for cleanliness and any oil spills. Clean or repair as needed.

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Weekly

An hour meter is useful to keep detailed records of genset maintenance.

Check the battery terminal connections for corrosion and looseness. Check for integrity of wire connections from the battery to the starter connections. Check the coolant level on the radiator. Refill as necessary. Check the engine oil for proper level and refill as necessary. Replace oil and filter as per manufacturer's recommendation. Check the fuel connections for leaks (for gas fuel). Get qualified personnel for immediate repair. Verify that the battery charger is working as expected. Test load operate the generator for preparedness. Record all front panel parameters. Verify that operation shows proper voltage regulation and frequency.

Monthly:

Check battery voltage with a DMM and record readings. Check electrolyte level and specific gravity. Take appropriate action as needed (for lead-acid battery only). Check the air filter. Replace as necessary. Check water hoses for cracks or leaks and replace as necessary.

Annually:

Load bank testing, compression and timing checks by qualified manufacturer's representative. CHANGE OIL USUALLY TAKES PLACE EVERY 250 HOURS OR SIX MONTHS

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