Four Common Mistakes That Can Reduce The Lifespan of Diesel Generator

Generally, a generator's lifespan depends on multiple variables. On average, diesel generators last from 10,000 to 30,000 hours of use, which could be upward of 25 years or more of running constantly. Proper operation and maintenance of generator are essential to long-term system reliability that ensures availability and uptime. Improper operation may reduce the lifespan of diesel generator. Below are common four mistake to avoid when using your diesel powered generator.

Reduce the engine speed for a long time

Revolutions Per Minute (RPM) is a measure of the speed at which a diesel generator operates. The RPM rating of a generator can affect its noise level. Generator frequency is the number of electrical cycles per second, measured in Hertz (Hz) and this is directly proportional to the engine speed. For example, a diesel generator has a RPM rating of 1500rpm and the frequency is 50Hz. The rated voltage is 400V. This mode of operation is relatively fast and therefore produces loud noise.

Some users reduce the speed in order to reduce the noise. This will cause insufficient voltage and frequency and result in a low or undervoltage operating state, which directly affects the use of equipment. In the long run, the power of diesel generator will decrease. A diesel generator running with load not at the rated speed for a long time can affect its lifespan.

Improper use of coolant

Water is a common coolant for liquid-cooling diesel generators. However, water quality can vary based on location. If tap water or river water is added to the radiator as the coolant, it can lead to buildup within the generator cooling system. Because water alone presents the possibility of corrosion, mineral deposits, and freezing. If you want to use water as coolant in diesel engine, choose de-mineralized water that is slightly alkaline with a pH of 8 to 9.5.

When the internal water temperature of the diesel generator set exceeds 80 °C, the bypass valve of the thermolator will be completely closed and the outlet valve will be fully opened, and the coolant will be completely circulated through the radiator. If the valve cannot be opened because of water scale problems, it may cause the genset to overheat. Without the four protective functions, this situation may not be easy to detect. Prolonged operation in such situation will cause damage to the components of the diesel engine.

Do not add or replace oil as required

Oil is a critical component in a diesel generator because it provides the lubrication to critical components, reduces friction, and helps in heat dissipation. The oil ensures the smooth operation and longevity of the engine. If it is not maintained for a long time, it may lead to oil reduction or deterioration. Oil will be much less effective as a lubricant due to changes in the oil viscosity or loss of additives over time. This can cause more friction and wear in your engine components. Insufficient oil can also cause the problem.

Thus, you need to check the oil regularly and top it up if necessary. Use oil that meets the specifications provided by the generator’s manufacturer and change the oil as per the manufacturers stated interval. This ensures proper lubrication and efficient performance and prolongs the life of your generator.

Start or stop the generator suddenly under load

The thermal shock of sudden heating or cooling is undesirable. Diesel generators need to be preheated for a few minutes before normal operation in a low temperature environment. Stopping a diesel generator suddenly without removing load can cause the carbon brush degaussing of a brushed generator. The sudden shutdown generator after a long period of operation with load will also cause heat dissipation problems. It is easy to cause overheating of the cylinder head, cylinder liner and cylinder block, resulting in cracks. It may also make the piston stuck in the cylinder liner due to excessive expansion.

A sudden shutdown during loaded operation is considered to be poor practice. Most engine manufacturers recommend that disconnect the load and run the generator 2-3 minutes at no load or idle before shutdown. When starting the diesel generator, you should run the generator at idle and then gradually speed up to the rated speed and then connect the load.

Any improper operation of the diesel generator set will directly or indirectly affect its lifespan. Proper operation and maintenance can help extending your generator’s lifespan. It’s important to Understand your generator’s needs to keep your generator up and running. Looking for a diesel generator? Feel free to contact us with any questions, concerns, or inquiries to learn more about the products & services we provide.