Generator Service Companies in Sri Lanka

Any generator set used for emergency or primary source must have periodic service and maintenance performed. Setting up a planned maintenance schedule, and performing all associated testing will insure generator availability upon demand. Possibilities of generator failure increase when service and maintenance checks are not performed.

CAUTION
The templates on this page are forreference only and to establish the basic contents of   a planned maintenance schedule. Always create the planned maintenance schedule in accordance with manufacturer’s guidelines.

Concept of Planned Maintenance

Planned maintenance can be defined as performing service, maintenance, inspections and testing on a generator set on a pre-determined schedule. Each maintenance program should include inspections for the status listed below:

• Calendar Cycle Schedule – Depending on manufacturer recommendations and applications, cycles can be divided into weekly, monthly, quarterly, semi-annual and annual requirements.
• Operating Inspections – Inspections to be performed on generator when operating. Critical operations can be monitored 100% of operating time. Non-critical operations can have basic checks performed as determined by application.
• Layup – Generator are placed in layup when no longer in active use. Basic outline of steps for generator layup.

A selected generator style (Portable, Skid and Weathertight Enclosure) will be featured to illustrate the basic creation of the inspection.

The final section introduces Generator Source as a provider for Service Contracts for all generator sets sold.

Visual Checks

WARNING
Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 120°F (50°C) before removing pressure cap. Heated coolant spray or steam can cause injury.

All planned maintenance charts define checks to be completed at a calendar interval. Coolant, lubricating oil and coolant levels can be at normal levels, but can be contaminated. When performing normal maintenance inspections look for the following:

• Air Restriction Indicator – Indicates when air restriction to intake is greater than manufacturer specifications. Red in color means change air filter (scheduled or not). Generally indictor located on air filter housing. Can be reset after filter change.
• Fuel Water Separator – This filter separates water from fuel contaminated with water. Water is routed to bottom bowl and can drain via valve. This can indicate main fuel source supply is contaminated.
• Water Indicating Paste – Used to test main fuel supply. Spread on tank level stick. Pink in color with no water. Turns red when fuel is contaminated with water. Generally water at the lower section of tank.
• Oil in Coolant – Oil floating on the coolant when cooling system is at ambient temperature. Can appear milky after engine operation. Engine lubricating oil leak into cooling system. Can be cylinder head gasket, defective engine block or cylinder head. Defect is where oil pressure is higher than coolant pressure.
• Coolant in Oil – Oil has milky color on dipstick. Coolant leak into engine lubricating oil. Can be cylinder head gasket, defective engine block or cylinder head. Defect is where coolant pressure is higher than oil pressure.

Calendar Cycle Schedule

All generator manufacturers publish maintenance schedules broken down by a calendar schedule. Standard Maintenance Schedule is illustrated in (Table 1):

Events

Emergency standby generator systems should have at least two maintenance events per year performed. Examples listed below:

• Load Bank Testing – Generator is placed under load for a period of time using an external load bank tester.
• Confidence Test – Generator is placed under load for a period of time using facility as a load.
• Fluid Analysis – Lubricating oil, coolant and fuel analysis performed by laboratory.

Always follow manufacturer’s guidelines when performing maintenance, inspections and testing.

Operating Inspections

The application the generator is used in defines the inspections that need to be performed while in operation. Each application requires development of a different inspection.
Always consult manufacturer’s guidelines when designing inspections to be performed when the generator is operating. Consider recent repairs and add into inspection criteria.

Layup

When an emergency generator is removed from service for a permeate period of time it is placed in the layup status. Some basic steps to place a generator in layup can include:

• Disconnect generator batteries.
• Drain fuel system and change fuel filters.
• Drain coolant and change coolant filters.
• Replace air filters.
• Insure all intake and exhaust ports are covered.
• Disconnect all generator supply connections.

If shipping the generator all DOT regulations must be followed. Industrial shrink wrapping is offered by many companies and offers long term storage options 

Generator Source and Supply & Planned Maintenance & Service Contracts: 

Generator Source has expanded our service options to provide On-Site Service Contracts for most of the larger generators that we sell. We also provide a variety of on-site services for customer owned generators within our immediate multi-state region. Contact our staff today for more details.

How Does a Diesel Engine Work?

In today’s world, where fuel prices are increasing as a consequence of spiraling demand and diminishing supply, you need to choose a cost-effective fuel to meet your needs. Thanks to the invention of Rudolph Diesel, the diesel engine has proved to be extremely efficient and cost effective.

Diesel fuel is priced moderately higher than gasoline, but diesel has a higher energy density, i.e. more energy can be extracted from diesel as compared with the same volume of gasoline. Therefore, diesel engines in automobiles provide higher mileage, making it an obvious choice for heavy-duty transportation and equipment. Diesel is heavier and oilier compared with gasoline and has a boiling point higher than that of water.  And diesel engines are attracting greater attention due to higher efficiency and cost effectiveness.

The distinction lies in the type of ignition.  While gasoline engines operate on spark ignition, diesel engines employ compression – ignition for igniting the fuel. In the latter, air is drawn into the engine and subjected to high compression that heats it up.

This results in a very high temperature in the engine, much higher than the temperature attained in a gasoline engine. At peak temperature and pressure, diesel that is let into the engine ignites on account of the extreme temperature.

In a diesel engine, air and the fuel are infused into the engine at different stages, as opposed to a gas engine where a mixture of air and gas are introduced. Fuel is injected into the diesel engine using an injector whereas in a gasoline engine, a carburetor is used for this purpose. In a gasoline engine, fuel and air are sent into the engine together, and then compressed. The air and fuel mixture limits fuel compression, and hence the overall efficiency.

A diesel engine compresses only air, and the ratio can be much higher. A diesel engine compresses at the ratio of 14:1 up to 25:1, whereas in a gasoline engine the compression ratio is between 8:1 and 12:1. After combustion, the combustion by-products are removed from the engine through the exhaust.

For starting during cold months extra heat is provided through ‘glow plugs’. Diesel engines can either be two cycle or four cycle and are chosen depending on mode of operation. Air-cooled and liquid-cooled engines are the variants to be chosen appropriately.  It is preferable to use a liquid-cooled generator as it is quiet in operation and has evenly controlled temperature.

Advantages of a Diesel Engine

The diesel engine is much more efficient and preferable as compared with gasoline engine due to the following reasons:

• Modern diesel engines have overcome disadvantages of earlier models of higher noise and maintenance costs.  They are now quiet and require less maintenance as compared with gas engines of similar size
• They are more rugged and reliable
• There is no sparking as the fuel auto-ignites. The absence of spark-plugs or spark wires lowers maintenance costs
• Fuel cost per Kilowatt produced is thirty to fifty percent lower than that of gas engines
• An 1800 rpm water cooled diesel unit operates for 12,000 to 30,000 hours before any major maintenance is necessary. An 1800 rpm water cooled gas unit usually operates for 6000-10,000 hours before it needs servicing
• Gas units burn hotter than diesel units, and hence they have a significantly shorter life compared with diesel units

Applications & Uses for Diesel Engines

Diesel engines are commonly used as mechanical engines, power generators and in mobile drives. They find wide spread use in locomotives, construction equipment, automobiles, and countless industrial applications. Their realm extends to almost all industries and can be observed on a daily basis if you were to look under the hood of everything you pass by.

Industrial diesel engines and diesel-powered generators have construction, marine, mining, hospital, forestry, telecommunications, underground, and agricultural applications, just to name a few. Power generation for prime or standby backup power is the major application of today’s diesel generators.  Check out our article on the various types of engines and generators and their common applications for more examples.

Power Generators

Diesel powered generators, or electrical generator sets, are used in countless industrial and commercial establishments. The generators can be used for small loads, such as in homes, as well as for larger loads like industrial plants, hospitals, and commercial buildings. They can either be prime power sources or standby/back-up power sources.

They are available in various specifications and sizes.  Diesel generator sets rating 5-30 kW are typically used in simple home and personal applications like recreational vehicles.  Industrial applications cover a wider spectrum of power ratings (from 30 kW to 6 Megawatts) and are used in numerous industries throughout the globe. For home use, single-phase power generators are sufficient. Three-phase power generators are primarily used for industrial purposes.