Diesel Generator Overload: Consequences and Preventive Measures

Electricity has become an indispensable infrastructure in modern society. Diesel generator sets play an important role in the power supply system, as their stability and reliability are directly related to the continuity and security of power supply. Overloading a generator may cause many problems, it’s necessary to take effective measures to prevent the generator from overloading.

What happens if a diesel generator is overloaded?

Overload in a diesel generator means running the machine beyond its load limit specified in its manual. Overloading generator refers to a situation where the electrical load on the generator exceeds its rated capacity or design specifications. When a diesel generator is overloaded, it can lead to several issues:

Cause a fire or even an explosion due to overheating

A long period of overheating can cause a diesel generator to heat up and catch fire. If there’s a gas tank near the unit or you notice a spark, you may risk an explosion. It’s wise to have a professional inspect the equipment before it happens.

Increased engine wear and reduced generator lifespan

If the overload condition persists for an extended period of time, the generator becomes overheat. It can burn out the alternator and other generator components, which shorten the lifespan of the unit. Please note that when the engine overheats, the oil viscosity (thickness) will breakdown and result in excessive friction within internal components of engine, low oil pressure and most probable costly engine failure.

Damage other equipment as well as wiring and circuits in electrical systems

In addition to damaging the unit itself, generator overloading may also cause damage to the other machinery receiving power from it.

Increased fuel consumption and emissions

When the generator is used for a larger load, the fuel consumption will be higher. Excessive loads can cause the generator to consume more fuel than it normally would. Overloading a diesel generator can also cause increased emissions, which can be harmful to the environment.

How to prevent diesel generator overload?

Since overloading a diesel generator may have dire consequences, it’s necessary to avoid your generator from being overloaded. You can follow the tips below to prevent your generator from overloading:

Choose a right size diesel generator that can full fill your needs

When buying a diesel genset, you need to consider the current power requirements and unexpected extra loads in the future. Typically, choose a diesel generator with a rating at least 20% higher than your peak power requirement. A margin for error, and to account for unexpected extra loads, is vital. Avoid running your diesel generator at its flat-out maximum capacity for long periods.

Install overload protection devices

Installing overload protection devices within the electrical control panel of diesel generator sets is a direct and effective way to prevent overloading. Overload protection devices can continuously monitoring the current drawn by the generator and automatically disconnect the electrical power supply when current surpasses a set threshold. They guard the diesel generator sets by shutting down the engine if the load breaches its rated capacity.

Manage your generator usage

If you have a lot of appliances that need to run on a generator, it's necessary to manage your generator usage. Prioritize emergency equipment as well as items, equipment, and appliances that could be damaged or cause a loss during an extended power outage. Load management will prevent you from operating too many high-consuming devices simultaneously. Consider using the parallel option if you have an inverter generator to increase the wattage.

Maintain your diesel generator regularly

It's important to maintain the generator regularly to ensure that it is operating appropriately. A well-maintained diesel generator can provide reliable power when you need it most. Pay attention to the manufacturer’s suggestions for oil, air filter replacement and routine cleaning. Keeping your generator well serviced will help to avoid overload and ensure its optimum performance when needed.

Use diesel generator remote monitoring system

A diesel generator monitoring solution like Dingbo Cloud Service platform allows fuel monitoring, monitoring of diesel generator operation parameters and engine diagnostics, receiving electrical data from alternator and remote genset control. By installing monitoring instruments and sensors, the intelligent diesel gensets enable users to monitor real-time operating status of the generator set and various parameters, such as voltage, current, power, temperature, etc. Once any abnormal conditions are detected, users can take measures to deal with them timely.

Hope the information above can help you prevent your diesel generator from overloading. Don’t hesitate to reach out for any further information or assistance regarding to diesel generator sets. Contact us at dingbo@dieselgeneratortech.com, and we will gladly help you.